Chapter-5

Experimental Result and Discussion

5.1 Effect of Chilled Air Coolant on Surface Roughness

The quality of work material’s surfaces after undergone various manufacturing

processes particularly in turning operation is very important in determining the functional
performance of a component throughout the services. For the present study, only surface
roughness has been considered for assessment of the quality of product under dry, MQL
(minimum quantity lubricant) and chilled air coolant using vortex tube.

Surface finish is also an important index of machinability or grindability because

performance and service life of the machined ground component are often affected by its surface
finish, nature and extent of residual stresses and presence of surface or subsurface micro cracks,
if any, particularly when that component is to be used under dynamic loading or in conjugation
with some other mating part(s). Generally, good surface finish, if essential, is achieved by
finishing processes like grinding but sometimes it is left to machining. Even if it is to be finally
finished by grinding, machining prior to that needs to be done with surface roughness as low as
possible to facilitate and economize the grinding operation and reduce initial surface defects as
far as possible. The major causes behind development of surface roughness in continuous
machining processes like turning, particularly of ductile metals are:

 regular feed marks left by the tool tip on the finished surface
 irregular deformation of the auxiliary cutting edge at the tool-tip due
 vibration in the machining system
 built-up edge formation, if any
The obtained results yielded that the surface finish was slightly better with the application of the
chilled air coolant compared to dry and MQL. The highest surface roughness value, 1.17µm, was
obtained in Dry Cooling Environment. Whereas, the lowest surface roughness value, 0.521µm,
was obtained with chilled air coolant using vortex tube. The surface roughness value obtained
with chilled air coolant method showed a decreasing trend which were 0.596 µm, 0.535 µm and
0.512 µm at 570.02°C, 528.69°C and 508.39°C, respectively for cutting velocity of 100.53
m/min, 89.16 m/min and 62.83 m/min at the feed 0.1 mm/rev and depth of cut 0.5 mm. For feed
rate 0.12 mm/rev, 0.14 mm/rev and depth of cut 0.75mm, 1mm the data shows similar approach.

Table 5.1 Reduction in surface roughness due to using MQL and Chilled Air Coolant in Turning
SS202 Stainless Steel

Percentage
Environment Reduction in
Surface Roughness
Cutting
Depth of
Table Feed, Velocity, Chilled Turning
cut, t RPM
So (mm/rev) Vc Dry MQL air Turning with
(mm)
(m/min) coolant with chilled
MQL air
Surface Roughness, Ra
coolant
(µm)
500 62.832 0.935 0.923 0.911 1.28 2.57
0.14 630 79.168 0.957 0.937 0.917 2.09 4.18
800 100.5312 0.975 0.957 0.939 1.85 3.69
500 62.832 0.756 0.729 0.702 3.57 7.14
0.5 0.12 630 79.168 0.767 0.754 0.741 1.69 3.39
800 100.5312 0.806 0.789 0.772 2.11 4.22
500 62.832 0.558 0.535 0.512 4.12 8.24
0.1 630 79.168 0.607 0.571 0.535 5.93 11.86
800 100.5312 0.644 0.62 0.596 3.73 7.45
500 62.832 1.023 0.987 0.974 3.52 4.79
0.14 630 79.168 1.014 1.003 0.992 1.08 2.17
800 100.5312 1.045 1.03 1.015 1.44 2.87
500 62.832 0.818 0.809 0.8 1.10 2.20
0.5 0.12 630 79.168 0.828 0.811 0.794 2.05 4.11
800 100.5312 0.845 0.818 0.791 3.20 6.39
500 62.832 0.607 0.601 0.595 0.99 1.98
0.1 630 79.168 0.624 0.616 0.608 1.28 2.56
800 100.5312 0.642 0.64 0.638 0.31 0.62
0.5 0.14 500 62.832 1.044 1.017 0.99 2.59 5.17
630 79.168 1.09 1.069 1.048 1.93 3.85
 800 100.5312 1.17 1.138 1.106 2.74 5.47
500 62.832 0.874 0.833 0.792 4.69 9.38
0.12 630 79.168 0.902 0.865 0.828 4.10 8.20
800 100.5312 0.942 0.908 0.874 3.61 7.22
500 62.832 0.665 0.648 0.631 2.56 5.11
0.1 630 79.168 0.669 0.661 0.653 1.20 2.39
800 100.5312 0.691 0.678 0.665 1.88 3.76

Table 5.1 shows the reduction percentage in surface roughness for MQL and chilled air coolant
with respect to dry condition. In both cases the surface roughness is reduced. The average
reduction percentage of surface roughness for MQL with respect to dry is 2.47%. While applying
chilled air coolant the surface roughness reduces more. The average reduction percentage for
chilled air coolant with respect to dry is 4.85%.

This is due to the fact that chilled air with lower temperature could remove the accumulated heat
at the cutting zone [8]. Although the surface roughness for chilled air coolant was only slightly
lower than conventional coolant, this cooling method was still better compared to the
conventional coolant.

These findings are in agreement with those obtained by Tosun et al. [9] which discovered that
the surface roughness values with the use of air cooling method are better than that of
conventional cooling method. The cooling capability increased when air was compressed and
cooled because high pressure air was capable to penetrate the interface between workpiece and
cutting tool. Other than that, high pressure air could blow the chip away so that the chip would
not scratch the surface of the workpiece. Chilled air coolant reduced the formation of built up
edge. Therefore, the surface finish improved.

5.2 Effect of Chilled Air Coolant on Temperature at Chip Tool Interface

During machining any ductile materials, heat is generated at the (a) primary deformation zone

due to shear and plastic deformation, (b) chip-tool interface due to secondary deformation and

sliding (c) work-tool interfaces due to rubbing. All such heat sources produce maximum

temperature at the chip-tool interface, which substantially influence the chip formation mode,
cutting forces and tool life. Therefore, attempts are made to reduce this detrimental cutting

temperature. Conventional cutting fluid application may, to some extent, cool the tool and the

Job in bulk but cannot cool and lubricate expectedly and effectively at the chip-tool interface

where the temperature is high. This is mainly because the flowing chips make mainly bulk

contact with the tool rake surface and may be followed by elastic contact just before leaving the

contact with the tool. Bulk contact does not allow the culling fluid to penetrate in the interface,

Elastic contact allows slight penetration of the culling fluid only over a small region by capillary

action. The cutting fluid action becomes more and more ineffective at the interface with the

increase in cutting velocity (Vc) when the chip-tool contact becomes almost fully plastic or

bulk.

The machining temperature at the cutting zone is an important index of machinability and needs

to be controlled as far as possible. Cutting temperature increases with the increase in specific

energy consumption and material removal rate (MRR). Such high cutting temperature adversely

affects, directly and indirectly, chip formation, cutting forces, tool life and surface integrity of

the products, Therefore, application of cooling air at chip tool interface is expected to improve

upon the aforesaid machinability characteristics that play vital role on productivity, product

quality and overall economy in addition environment-friendliness in machining particularly

when the cutting temperature is very high.

Table 5.2 Reduction in Temperature due to using MQL and Chilled Air Coolant in Turning

SS202 Stainless Steel

Percentage
Environment Reduction in
Dept Cutting Temperature
Table
h of Velocity, Dry MQL Chilled air coolant Turnin
Feed, So RPM
cut, t Vc Turnin g with
(mm/rev)
(mm) (m/min) g with chilled
Temperature Ɵ֯ C MQL air
coolant
548.587
0.97 6.84
500 62.832 553.96 3 516.0925
560.185
0.14 2.14 9.84
630 79.168 572.42 6 516.0925
100.531 575.352
3.55 13.49
800 2 596.56 8 516.0925
532.332
1.50 4.51
500 62.832 540.46 9 516.0925
560.17
0.5 0.12 1.23 7.87
630 79.168 5 553.281 516.0925
100.531 585.95
0.90 11.92
800 2 5 580.666 516.0925
516.092
2.06 2.06
500 62.832 526.96 5 516.0925
547.22 546.376
0.1 0.16 5.69
630 79.168 9 3 516.0925
100.531 585.979
-1.85 10.30
800 2 575.35 2 516.0925
577.89 561.970
2.76 10.69
500 62.832 6 1 516.0925
599.53 578.052
0.14 3.58 13.92
630 79.168 2 2 516.0925
100.531 627.82 599.082
4.58 17.80
800 2 4 7 516.0925
564.52
3.08 8.58
500 62.832 7 547.155 516.0925
0.5
587.42 567.784
0.12 3.34 12.14
630 79.168 9 1 516.0925
100.531 617.35 595.176
3.59 16.40
800 2 6 2 516.0925
551.15 532.339
3.41 6.36
500 62.832 6 9 516.0925
0.1
575.30 557.875
3.03 10.29
630 79.168 7 9 516.0925
 100.531 606.88 591.269
2.57 14.96
800 2 9 6 516.0925
601.83 575.352
4.40 14.25
500 62.832 3 8 516.0925
626.64 595.918
0.14 4.90 17.64
630 79.168 3 7 516.0925
100.531 659.08 622.812
5.50 21.70
800 2 7 5 516.0925
588.59 561.970
4.52 12.32
500 62.832 3 1 516.0925
614.68 582.287
0.5 0.12 5.27 16.04
630 79.168 4 1 516.0925
100.531 645.75 609.686
5.59 20.08
800 2 7 3 516.0925
575.35 548.587
4.65 10.30
500 62.832 3 3 516.0925
602.68 569.375
0.1 5.53 14.37
630 79.168 5 4 516.0925
100.531 638.42
6.56 19.16
800 2 7 596.56 516.0925

It is observed in table 5.2 that applying chilled air coolant using vortex tube enabled reduction of

the average cutting temperature. While applying chilled air coolant the average reduction in

temperature is 12.20% with respect to dry machining. In MQL method the average reduction in

temperature is 3.24%. So, chilled air coolant produces the least temperature in chip tool

interface. Apparently, reduction in the cutting temperature is expected to have some favorable

influence on other machinability indices.