Particulate matter – monitoring during end milling under different cooling-lubrication strategies

doi:10.6180/jase.202112_24(6).0010

Particulate matter – monitoring during end milling under different cooling-lubrication strategies

M.S. Kasim ^1,2, N.H.N. Husshini^1,2, M.S.A. Hafiz^1,2, W.N.F.Mohamad^1,2,4, R.Izamshah^1,2, J.A Ghani³, and C.H.C Haron³

1Fakulti Kejuruteraan Pembuatan, Universiti Teknikal Malaysia Melaka, 76100, Hang Tuah Jaya, Melaka, Malaysia
2Advanced Manufacturing Centre, Universiti Teknikal Malaysia Melaka, 76100, Hang Tuah Jaya, Melaka, Malaysia
3Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600, Bangi, Selangor, Malaysia
4Fakulti Rekabentuk Inovatif dan Teknologi, Universiti Sultan Zainal Abidin, 21300, Kuala Terengganu, Terengganu, Malaysia

Received: November 22, 2020
Accepted: March 11, 2021
Publication Date: June 23, 2021

Copyright The Author(s). This is an open access article distributed under the terms of the Creative Commons Attribution License (CC BY 4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are cited.

Download Citation: ||https://doi.org/10.6180/jase.202112_24(6).0010

ABSTRACT

Many lubrication strategies have been applied in cutting processes. The main purpose is to reduce heat generated and to lower friction on the cutting tool thus improving the surface quality of the workpiece. However, the quality of indoor air has become a major health and safety issue. This study explains the effects of cooling, lubrication strategies and cutting parameters on particulate matter emission. The experiments involved the use of TiCN CVD coated carbide with varying cutting speeds (Vc), feed rates (fz), and cooling-lubrication strategies (dry, chilled air, chilled MQL, MQL, flood-coolant and pulsating lubrication) for both Aluminium alloy 6061 and Inconel 718. Design of experiment and analysis of variance (ANOVA) were used to examine the effects of the input parameters on the PM2.5 value. Based on ANOVA, it was found that the chilled MQL and MQL exhibited high PM2.5 readings, while the other coolant strategies yielded results which were within an acceptable exposure limit.

Keywords: Particulate Matter; End milling; Eco-friendly Cooling-lubrication strategy; Aluminium alloy 6061; Inconel 718

REFERENCES

[1] Adhip Shukla, Aman Kotwani, and Deepak Rajendra Unune. Performance comparison of dry, flood and vegetable oil based minimum quantity lubrication environments during CNC milling of Aluminium 6061. In Materials Today: Proceedings, volume 21, pages 1483–1488. Elsevier Ltd., 2020. .

[2] Mohd Asyraf Mahboob Ali, Azwan Iskandar Azmi, and Ahmad Nabil Mohd Khalil. Specific cutting energy of Inconel 718 under dry, chilled-air and minimal quantity nanolubricants. In Procedia CIRP, volume 77, pages 429–432. Elsevier B.V., 2018.

[3] Alborz Shokrani and Stephen T. Newman. Hybrid cooling and lubricating technology for CNC milling of Inconel 718 nickel alloy. In Procedia CIRP, volume 77, pages 215–218. Elsevier B.V., 2018.

[4] D. Dudzinski, A. Devillez, A. Moufki, D. Larrouquère, V. Zerrouki, and J. Vigneau. A review of developments towards dry and high speed machining of Inconel 718 alloy. International Journal of Machine Tools and Manufacture, 44(4):439–456, 2004. ISSN 08906955. .

[5] G. Byrne and E. Scholta. Environmentally Clean Machining Processes - A Strategic Approach. CIRP Annals - Manufacturing Technology, 42(1):471–474, jan 1993. ISSN 17260604. .

[6] S. Y. Hong and M. Broomer. Economical and ecological cryogenic machining of AISI 304 austenitic stainless steel. Clean Products and Processes, 2(3):0157–0166, nov 2000. ISSN 1618954X. .

[7] M. S. Najiha, M. M. Rahman, and K. Kadirgama. Machining performance of aluminum alloy 6061-T6 on surface finish using minimum quantity lubrication. International Journal of Automotive and Mechanical Engineering, 11(1): 2699–2712, 2015. ISSN 21801606. .

[8] M. S.A. Hafiz, M. S. Kasim, R. Izamshah, W. N.F. Mohamad, A. Abdullah, and M. F. Jaafar. An assessment for a new approach to pulsating lubrication strategy (PLS) in end milling. International Journal of Advanced Manufacturing Technology, 105(7-8):3157–3163, 2019. ISSN 14333015.

[9] M. A. Hadi, J. A. Ghani, C. H. Che Haron, and M. S. Kasim. Investigation on wear behavior and chip formation during up-milling and down-milling operations for inconel 718. Jurnal Teknologi (Sciences and Engineering), 66(3):15–21, 2014. ISSN 01279696. .

[10] M.A. Sulaiman, M.S. Asiyah, R. Shahmi, E. Mohamad, N.A. Mohamad, M.A. Md Ali, D. Yuniawan, and T. Ito. Effect of Cutting Parameter on the Tool Life of the uncoated carbide tool during turning using Minimum Quantity Lubrication (MQL). 2017.

[11] Yaolin Lin, Jiale Zou, Wei Yang, and Chun Qing Li. A review of recent advances in research on PM2.5 in China, 2018. ISSN 16604601.

[12] San Salvador and El Salvador. Overview of Particle Air Pollution (PM2.5 and PM10), 2012. URL https://www.epa.gov/sites/production/files/2014-05/ documents/huff-particle.pdf.

[13] Robert W. Kolb. National Ambient Air Quality Standards (NAAQS). In The SAGE Encyclopedia of Business Ethics and Society, number 4, pages 1–2. SAGE Publications, Inc., 2455 Teller Road, 2018. .

[14] United States Environmental Protection Agency. No Title URL https://www.epa.gov/sites/production/files/ 2015 02/documents/criteria.pdf.

[15] Final Rule. National Ambient Air Quality Standards. Part II AGENCY. 78(10), 2013.

[16] Ellen A Eisen, Thomas J Smith, David Kriebel, Susan R Woskie, Douglas J Myers, Susan M Kennedy, Stuart Shalat, and Richard R Monson. Respiratory health of automobile workers and exposures to metal-working fluid aerosols: Lung spirometry. American journal of industrial medicine, 39(5):443–453, 2001.

[17] I. P. Okokpujie, C. A. Bolu, O. S. Ohunakin, E. T. Akinlabi, and D. S. Adelekan. A review of recent application of machining techniques, based on the phenomena of CNC machining operations. In Procedia Manufacturing, volume 35, pages 1054–1060. Elsevier B.V., 2019. .

[18] Kun Li, Fereydoun Aghazadeh, Selen Hatipkarasulu, and Thomas G. Ray. Health risks from exposure to metalworking fluids in machining and grinding operations. International Journal of Occupational Safety and Ergonomics, 9(1):75–95, jan 2003. ISSN 10803548. .

[19] Abdelhakim Djebara, Victor Songmene, and Ali Bahloul. Effects of machining conditions on specific surface of PM<sub>2.5</sub> emitted during metal cutting. Health, 05(10):36–43, 2013. ISSN 1949-4998. .

[20] HSE BOOK. Medical aspects of occupational skin disease. 24:1–17, 2004.

[21] A.-M. El-Batahgy, B. Terad, and A. Omar. Effect of friction stir welding parameters on properties of AA6061 aluminum alloy butt welded joints. In Proceedings of the 1st International Joint Symposium on Joining and Welding, pages 33–40. Elsevier, 2013. .

[22] A. H. Musfirah, J. A. Ghani, and C.H. H.Che Haron. Tool wear and surface integrity of inconel 718 in dry and cryogenic coolant at high cutting speed. Wear, 376-377: 125–133, apr 2017. ISSN 00431648. .

[23] Mozammel Mia, Munish Kumar Gupta, Gurraj Singh, Grzegorz Królczyk, and Danil Yu Pimenov. An approach to cleaner production for machining hardened steel using different cooling-lubrication conditions. Journal of Cleaner Production, 187:1069–1081, jun 2018. ISSN 09596526. .