Helical Milling of CFRP/Ti6Al4V Stacks Using Nano Fluid Based Minimum Quantity Lubrication (NF-MQL): Investigations
Kiran Mughal1, Mohammad Pervez Mughal2, Muhammad Umar Farooq1,3
1Department of Industrial and Manufacturing Engineering, University of Engineering and Technology Lahore, Lahore 54890, Pakistan.
Materials (Basel, Switzerland)
|January 21, 2023
Summary
This study introduces nano fluid based minimum quantity lubrication (NF-MQL) for helical milling of CFRP/Ti6Al4V stacks, significantly improving hole integrity and reducing surface roughness and tool wear for cleaner production.
Area of Science:
- Materials Science and Engineering
- Manufacturing Processes
- Tribology
Background:
- Machining composite-metal stacks like CFRP/Ti6Al4V presents challenges in hole integrity due to material property differences.
- Existing processes struggle with quality variations in machined holes, impacting aeronautical component reliability.
- Thermal properties and processability limitations hinder effective machining of these dissimilar materials.
Purpose of the Study:
- To investigate the efficacy of nano fluid based minimum quantity lubrication (NF-MQL) in helical milling of CFRP/Ti6Al4V stacks.
- To analyze the influence of machining parameters on hole accuracy, surface roughness, processing temperature, and tool wear.
- To optimize the NF-MQL process for enhanced hole integrity and cleaner production.
Main Methods:
- Helical milling of CFRP/Ti6Al4V stacks utilizing nano fluid based minimum quantity lubrication (NF-MQL).
- Analysis of Variance (ANOVA) to determine the significance of parameters like spindle speed, feed rate, and eccentricity on diametric and circularity errors.
- Evaluation of surface roughness, processing temperature, and tool wear (flank and edge wear) under varying MoS2 concentrations in the lubricant.
Main Results:
- Significant parameters for diametric error in Ti6Al4V include spindle speed and eccentricity; for CFRP, tangential feed and spindle speed are critical.
- Increased tangential feed led to higher circularity error due to prolonged tool engagement.
- Surface roughness of Ti6Al4V improved with higher MoS2 concentration, and processing temperature was influenced by spindle speed and lubricant type.
- Spindle speed, tangential feed, and lubrication significantly controlled flank wear, while MoS2 concentration reduced edge wear.
Conclusions:
- NF-MQL is a novel and effective solution for improving hole integrity and process performance in machining CFRP/Ti6Al4V stacks.
- Optimized machining parameters and lubricant composition (e.g., MoS2 concentration) are crucial for minimizing errors and tool wear.
- The study demonstrates a pathway towards cleaner production by enhancing machining efficiency and component quality.
