Experimental investigation of the effects of machining parameters and lubrication on consumed power and surface roughness in CK45 steel milling

Gholipoor, Ahad; Zakeri Mehrabad, Vahid; Hejavari, Ata

Experimental investigation of the effects of machining parameters and lubrication on consumed power and surface roughness in CK45 steel milling

Authors

Ahad Gholipoor ¹

vahid zakeri mehrabad ²

Ata hejavari ³

¹ MSc. in Manufacturing Eng/ Islamic Azad University of Tabriz

² MSc. in Mechanical Eng., Islamic Azad Univ., Tabriz Branch

³ BSc. Student of Mechanical Eng., Islamic Azad Univ., Tabriz Branch

Abstract

In this paper, in order to avoid the problems induced by cutting liquids like higher cost, environmental pollution and dangerous for operator health in milling process and also using the benefits of them such as increasing tool life and machined surface quality, machining by minimum quantity of lubrication (MQL) or near dry lubrication was introduced and that’s effects on main outputs (consumed power and surface roughness) was compared with other lubrication methods such as lubrication by cutting fluids and by air. In order to perform a series of experiments and investigate the effects of different process parameters such as tools rotational speed, feed rate, gas pressure and liquid flow rate on main outputs, the Taguchi method of design of experiments was employed and then the analysis of variance (ANOVA) was used to find the most important factors effecting main outputs. The results obtained by experiments showed that employing near dry lubrication leads to lower electrical power and comparable surface roughness as compared with other lubrication methods. The analysis of variance showed that feed rate is the most important factor affecting consumed power and liquid flow rate is the most important factor influencing surface roughness.

Keywords

milling

Minimum Quantity Lubrication (MQL)

Taguchi method

Electrical Power

Surface roughness