Numerical Analysis And Experimental Investigation Of Turning Operation Using Solid Lubricant

Abstract

Machining of material is one of the basic need of manufacturing industries. Turning operation is rudimentary process in machining. Many industries and researchers are working in a direction to improve quality and quantity of the product at the same time. Cutting speed, Feed and Depth of cut are cardinal process parameters to determine the quality and quantity of the product produced in process. Turning operation is a material removal process. Considerable amount of heat is generated in meal removing process. Surface finish and heat generated during the process are influenced by process parameter. In turning operation heat generated is one of the cause for poor quality of product produced and tool wear. Various cooling techniques are used to control heat generated during the process. In present work we have observed the effect of each cooling techniques and process parameter on the surface finish and heat generated during the turning operation. Effects of feed, depth of cut and cutting speed were observed as well as effect of minimum quantity lubricants (MQL) with solid lubricants were investigated. Experiments were performed on KIRLOSKAR TURNMASTER 35 lathe machine with CNMG120404 grade TN2000 tool. Graphite and molybdenum disulfide were selected as solid lubricants. Tool-chip interface temperature measurement by conventional method is expedient. Complete setup of tool-work thermocouple was made on late machine. Calibration of thermocouple was done using hot air oven and oxy-acetylene flames. Design of experiment was done using response surface methodology (optimal) to acquire trials of experiment. For all different cutting condition set of trials were iterated. From the acquired results mathematical model was made. Post analysis was done using Design expert 10 (Response surface methodology). Combined and individual effect of process parameter were observed for each trials of experiment. To validate the mathematical model, simulation for turning operation were performed on ANSYS workbench 16.2. It was found that feed is the most influential process parameter for surface finish produced and temperature generated at tool-chip interface is influenced by depth of cut. Heat generated at tool-chip interface and Surface finish of the product is more satisfactory in case of machining with molybdenum disulfide.