Optimization of lubrication techniques on machining performance of aluminium alloy 319

Traditionally, the selection of cutting parameters for machining was left to the machine operator. In industries, the machining parameters are dependent on the experience and skill of the machine operator to achieve an optimal product quality. The disadvantage of this unscientific practice is low in...

Full description

Bibliographic Details
Main Author:	Zainal Ariffin, Selamat
Format:	Thesis
Language:	English
Published:	2018
Subjects:	TJ Mechanical engineering and machinery TS Manufactures
Online Access:	http://umpir.ump.edu.my/id/eprint/25592/ http://umpir.ump.edu.my/id/eprint/25592/ http://umpir.ump.edu.my/id/eprint/25592/1/Optimization%20of%20lubrication%20techniques%20on%20machining%20performance%20of%20aluminium.pdf

id	ump-25592
recordtype	eprints
spelling	ump-255922019-08-06T04:41:32Z http://umpir.ump.edu.my/id/eprint/25592/ Optimization of lubrication techniques on machining performance of aluminium alloy 319 Zainal Ariffin, Selamat TJ Mechanical engineering and machinery TS Manufactures Traditionally, the selection of cutting parameters for machining was left to the machine operator. In industries, the machining parameters are dependent on the experience and skill of the machine operator to achieve an optimal product quality. The disadvantage of this unscientific practice is low in productivity due to the sub optimal use of machining capability. The challenges in the modern machining industries are mainly focused on the machining performance on the surface roughness, temperature and tool life with reducing the coolant utilization. The objective of this research is to optimize nozzle lubricant system in machining performance of aluminum alloy 319 (A319) to achieve a good surface roughness, lower temperature and increased tool wear by selecting suitable machining parameters of cutting speed, depth of cut and feed rate. The coolant system used are dry, wet and optimum coolant nozzle size of 1.0 mm, 2.0 mm, 3.0 mm 4.0 mm and 5.0 mm on the surface roughness, temperature and tool life using Respond Surface Method (RSM) on the CNC Lathe machine with 2 axes movements. The surface roughness is measured using Surface Roughness Tester, temperature is measured using Infrared Laser Thermometer and tool wear is measured using Tool Maker’s Microscope. The synthetic soluble oils, coated cemented carbide Al2 O3 insert and Aluminum alloy 319 were used as a cutting tool and workpiece material respectively. The effect of cutting parameters towards surface roughness, temperature and tool wear were analyzed using Analysis of Variance (ANOVA) method and to achieve optimum machining performance by using Respond Surface Method (RSM). Multi-optimization of cutting parameters is used in ensuring product quality and minimizing the energy effects of machining. The results of the nozzle size of 1.0 mm shows a good surface roughness, lower temperature and reduced tool wear compared to 2.0 mm, 3.0 mm, 4.0 mm and 5.0 mm nozzle size. In lubrication techniques experiment, the analysis using ANOVA show that the main factor affecting the surface roughness, temperature and tool wear as machining performance is the used nozzle size of 1.0 mm. Cutting speed of 270 m/min, depth of cut of 0.20 mm, feed rate of 0.08 mm/min and nozzle size lubrication techniques of 1.0 mm are the optimum parameters for improving and achieving the surface roughness of 0.94 μm Ra, temperature of 91C, tool wear length of 0.48 mm and the machining time taken is 120 minutes for tool life. The optimum parameters setting are verified with experimental validation with maximum 4 percent error and obtained optimal desirability value of 0.935 for the respective values of cutting speed, depth of cut, feed rate and coolant nozzle of 1.0 mm. In conclusion, the optimum overall performance in terms of surface roughness, temperature and tool wear with the smallest orifice size coolant and different cutting parameters can be developed using RSM technique. Current research is also beneficial to minimize and improve the productivity in machining industries. Consequently, reducing the dependent on the machining operators experience and skill. 2018-11 Thesis NonPeerReviewed pdf en http://umpir.ump.edu.my/id/eprint/25592/1/Optimization%20of%20lubrication%20techniques%20on%20machining%20performance%20of%20aluminium.pdf Zainal Ariffin, Selamat (2018) Optimization of lubrication techniques on machining performance of aluminium alloy 319. PhD thesis, Universiti Malaysia Pahang. http://iportal.ump.edu.my/lib/item?id=chamo:105491&theme=UMP2
repository_type	Digital Repository
institution_category	Local University
institution	Universiti Malaysia Pahang
building	UMP Institutional Repository
collection	Online Access
language	English
topic	TJ Mechanical engineering and machinery TS Manufactures
spellingShingle	TJ Mechanical engineering and machinery TS Manufactures Zainal Ariffin, Selamat Optimization of lubrication techniques on machining performance of aluminium alloy 319
description	Traditionally, the selection of cutting parameters for machining was left to the machine operator. In industries, the machining parameters are dependent on the experience and skill of the machine operator to achieve an optimal product quality. The disadvantage of this unscientific practice is low in productivity due to the sub optimal use of machining capability. The challenges in the modern machining industries are mainly focused on the machining performance on the surface roughness, temperature and tool life with reducing the coolant utilization. The objective of this research is to optimize nozzle lubricant system in machining performance of aluminum alloy 319 (A319) to achieve a good surface roughness, lower temperature and increased tool wear by selecting suitable machining parameters of cutting speed, depth of cut and feed rate. The coolant system used are dry, wet and optimum coolant nozzle size of 1.0 mm, 2.0 mm, 3.0 mm 4.0 mm and 5.0 mm on the surface roughness, temperature and tool life using Respond Surface Method (RSM) on the CNC Lathe machine with 2 axes movements. The surface roughness is measured using Surface Roughness Tester, temperature is measured using Infrared Laser Thermometer and tool wear is measured using Tool Maker’s Microscope. The synthetic soluble oils, coated cemented carbide Al2 O3 insert and Aluminum alloy 319 were used as a cutting tool and workpiece material respectively. The effect of cutting parameters towards surface roughness, temperature and tool wear were analyzed using Analysis of Variance (ANOVA) method and to achieve optimum machining performance by using Respond Surface Method (RSM). Multi-optimization of cutting parameters is used in ensuring product quality and minimizing the energy effects of machining. The results of the nozzle size of 1.0 mm shows a good surface roughness, lower temperature and reduced tool wear compared to 2.0 mm, 3.0 mm, 4.0 mm and 5.0 mm nozzle size. In lubrication techniques experiment, the analysis using ANOVA show that the main factor affecting the surface roughness, temperature and tool wear as machining performance is the used nozzle size of 1.0 mm. Cutting speed of 270 m/min, depth of cut of 0.20 mm, feed rate of 0.08 mm/min and nozzle size lubrication techniques of 1.0 mm are the optimum parameters for improving and achieving the surface roughness of 0.94 μm Ra, temperature of 91C, tool wear length of 0.48 mm and the machining time taken is 120 minutes for tool life. The optimum parameters setting are verified with experimental validation with maximum 4 percent error and obtained optimal desirability value of 0.935 for the respective values of cutting speed, depth of cut, feed rate and coolant nozzle of 1.0 mm. In conclusion, the optimum overall performance in terms of surface roughness, temperature and tool wear with the smallest orifice size coolant and different cutting parameters can be developed using RSM technique. Current research is also beneficial to minimize and improve the productivity in machining industries. Consequently, reducing the dependent on the machining operators experience and skill.
format	Thesis
author	Zainal Ariffin, Selamat
author_facet	Zainal Ariffin, Selamat
author_sort	Zainal Ariffin, Selamat
title	Optimization of lubrication techniques on machining performance of aluminium alloy 319
title_short	Optimization of lubrication techniques on machining performance of aluminium alloy 319
title_full	Optimization of lubrication techniques on machining performance of aluminium alloy 319
title_fullStr	Optimization of lubrication techniques on machining performance of aluminium alloy 319
title_full_unstemmed	Optimization of lubrication techniques on machining performance of aluminium alloy 319
title_sort	optimization of lubrication techniques on machining performance of aluminium alloy 319
publishDate	2018
url	http://umpir.ump.edu.my/id/eprint/25592/ http://umpir.ump.edu.my/id/eprint/25592/ http://umpir.ump.edu.my/id/eprint/25592/1/Optimization%20of%20lubrication%20techniques%20on%20machining%20performance%20of%20aluminium.pdf
first_indexed	2023-09-18T22:39:23Z
last_indexed	2023-09-18T22:39:23Z
_version_	1777416812026134528

Optimization of lubrication techniques on machining performance of aluminium alloy 319

Similar Items