Experimental study of milling process using solid lubricant

Zulkifli, Farez Amsyar (2022) Experimental study of milling process using solid lubricant. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Milling process is a conventional cutting process which involves the use of physical cutting tool to remove the workpiece material. Involvement of physical cutting tool will lead to heat generation due to friction, which led to increase the thrust force, shorter cutting tool life due to wear and deformation, poor surface finish, and dimensional inaccuracy of the machined surface. Thus, lubrication is applied at the contact point of the cutting tool and workpiece during the process to reduce the friction. Though, conventional petroleum-based cutting fluid has always been known due to its not environmentally friendly as well as harmful to human. Solid lubricant is one of the alternatives due to its ecological properties. Solid lubricant of 90 nm sized molybdenum disulfide (MoS2) powder is mixed with palm oil at 0.02 wt%. The machining responses such as surface roughness, and thrust force during the milling process on mild steel plate is investigated. The control parameters are cutting speed, feed rate, and cooling condition. The applied cooling conditions are dry, minimum quantity lubrication (MQL) of only palm oil as base fluid, and solid lubricant minimum quantity lubrication (SLMQL) of MoS2 mixed with palm oil. Applying the Taguchi method, it was found that most influential parameter is cooling condition. Linear ANOVA from regression analysis found that increase of cutting speed improved the surface roughness and thrust force, meanwhile higher feed rate reduces surface roughness but increase the thrust force. As expected, SLMQL performs the best, followed by MQL, and dry.

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