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Title: Performance assessment of air-water and TiO2 nanofluid mist spray cooling during turning hardened AISI D2 steel
Authors: Kumar, Ramanuj
Sahoo, Ashok Kumar
Mishra, Purna Chandra
Das, Rabin Kumar
Keywords: Hard turning;Spray impingement cooling;Flank wear;Surface roughness;Chip-tool interface temperature;Tool life;TiO2 nano fluid;ANN modeling
Issue Date: Jun-2019
Publisher: NISCAIR-CSIR, India
Abstract: Spray cooling has greater potential to dissipate heat from the heating source. Application of spray cooling in hard turning (hardness ≥ 55 HRC) is a newer concept and rarely investigated. In present work, the hard turning of AISI D2 steel under air-water mist spray impingement cooling (SIC) environment has been carried using multilayer (TiN (bottom) / TiCN (middle) / Al2O3 (top)) coated carbide tool. Taguchi L16 (45 i.e. 5 factor such as cutting speed, feed, depth of cut, air pressure and water pressure and their 4 levels) orthogonal array-design of experiments have been chosen for the experimentations. The detailed investigation on machining responses like flank wear (VBc), surface roughness (Ra), chip-tool-interface temperature (T), chip morphology, chip reduction coefficient (CRC) and restricted chip-tool contact length (RCL) have been carried out. Tool-wear phenomena like micro-chipping, chipping, abrasion and severe abrasion have been majorly observed on tool-tip and highly affected by cutting speed. The higher magnitude of Ra (1.304 µm, 1.332 µm, 1.344 µm, and 1.420 µm) has been noticed with highest feed rate (0.16 mm/rev) machining condition. The chip-tool interface temperature under SIC surrounding ranges from 49.7ᵒC to 156.2ᵒC, which have been found very low for hard turning concern. Widely popular multi-response technique namely grey relational analysis (GRA) has been implemented to get the optimal combination of input variables. Further, stepwise preparation methodology of nano TiO2 powder and de-ionized water based TiO2 nanofluid (0.01% weight concentration) has been discussed briefly. The average size of TiO2 particle has been found as 10-20 nm. Further, tool life under two different (air-water and air-TiO2 nanofluid) spraying environments using optimal cutting condition has been evaluated and compared. The tool life under air-TiO2 nanofluid is found to be 119 minutes which is about 70 % more than the tool life (70 minutes) obtained under air-water spray cooling. From ANN modeling, mean absolute error (MAE) for response Ra, T and VBc have been found to be 2.1 %, 3.1 % and 1.9 %, respectively, which indicated the well fit of models.
Page(s): 235-253
ISSN: 0975-1017 (Online); 0971-4588 (Print)
Appears in Collections:IJEMS Vol.26(3&4) [June & August 2019]

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