Comparison Study Between The Effect Of Vortex Air Cooling And Conventional Cooling On Flank Wear And Surface Roughness

Yap, Hui Mei (2015) Comparison Study Between The Effect Of Vortex Air Cooling And Conventional Cooling On Flank Wear And Surface Roughness. Project Report. UTeM, Melaka, Malaysia. (Submitted)

Text (24 pages) Comparison Study Between The Effect Of Vortex Air Cooling And Conventional Cooling On Flank Wear And Surface Roughness 24 Pages.pdf - Submitted Version Download (439kB)

Abstract

In turning process, cutting fluid is used to reduce cutting temperature at tool-chip interface. A green machining is always preferable, so vortex air cutting is introduced. Vortex air helps to reduce cutting temperature at the tool-chip interface, without using cutting fluid that caused health hazard, pollution and a high cost have to spend on purchasing and treatment. Cold air is produced by compressed air without using any refrigerant and it is used to spot onto tool-workpiece interface. First experiment studied correlation between air pressure and vortex air temperature, while second experiment compared the flank wear and surface roughness between both vortex air cooling and conventional cooling. Vortex air temperature was measured by Hanna K-type thermocouple. For the second experiment, optimized machining parameters were used which are high cutting speed of 425rpm, low feed rate of 0.05mm/rev and 0.5mm depth of cut. A lathe machine, a Stereo Microscope and a Mitutoyo profilometer were used for machining, measuring flank wear as well as surface roughness respectively. The coefficient of determinant, R2 of first experiment is closed to 1 which means a strong correlation between air pressure and vortex air temperature. Based on ANOVA analysis, the second experiment indicated that both coolant type significantly influenced flank wear and surface roughness. For flank wear performance, conventional cooling was 2.4 times smaller than that of vortex air cooling. The main reason is the air is a poorer heat conductivity and lower specific heat convection. However, vortex air cooling made an improvement of 60% on surface roughness when compared to that of conventional cooling. This is because built up edge was prevalent for conventional cooling.

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