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<p>This current study comprehensively examines the influence of MQL process parameters, including nozzle types (Nn), nozzle distance (Nd), and nozzle flow rate (Nf), on machinability and sustainability factors such as flank wear, surface integrity, cutting power, cutting temperature, and carbon emissions during hard turning, utilizing a Taguchi L<sub>18</sub> orthogonal array design of experiments. The dual-jet nozzle has proven to be the most sustainable and efficient, with reductions of 8.43%, 12.82%, 11.4%, 19.2%, and 5.49% in VBc, Ra, Pc, T, and Ce, respectively, at the maximum flow rate and a nozzle distance of 30&#xa0;mm, in comparison with the single-jet nozzle MQL condition. The coating delamination of cutting tool found to be more severe in single-jet nozzle MQL than dual-nozzle MQL. Dual-nozzle MQL with in conjunction with high flow rate and medium level of nozzle distance provided a superior cooling facility which provides a smoother surface with minimal surface defects as evident from FESEM and AFM analysis of machined surface. A nozzle distance of 30&#xa0;mm, a flow rate of 50&#xa0;ml/hr, and a dual-jet nozzle MQL configuration were identified as the optimum parameters for simultaneously reducing flank wear, surface roughness, cutting power, cutting temperature, and carbon emissions. This parametric condition demonstrated a precise machining process, attaining a minimal circularity error of 0.010&#xa0;mm with a standard deviation of 0.012. </p>

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Performance Assessment of Single- and Dual-Jet Enriched MQL-Assisted Machining of Hardened Steel toward Environmental Sustainability

  • 期刊论文

  • 发表日期：

    2025年5月9日

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  • Saswat Khatai,
  • Ashok Kumar Sahoo,
  • Ramanuj Kumar,
  • Amlana Panda

摘要

This current study comprehensively examines the influence of MQL process parameters, including nozzle types (Nn), nozzle distance (Nd), and nozzle flow rate (Nf), on machinability and sustainability factors such as flank wear, surface integrity, cutting power, cutting temperature, and carbon emissions during hard turning, utilizing a Taguchi L18 orthogonal array design of experiments. The dual-jet nozzle has proven to be the most sustainable and efficient, with reductions of 8.43%, 12.82%, 11.4%, 19.2%, and 5.49% in VBc, Ra, Pc, T, and Ce, respectively, at the maximum flow rate and a nozzle distance of 30 mm, in comparison with the single-jet nozzle MQL condition. The coating delamination of cutting tool found to be more severe in single-jet nozzle MQL than dual-nozzle MQL. Dual-nozzle MQL with in conjunction with high flow rate and medium level of nozzle distance provided a superior cooling facility which provides a smoother surface with minimal surface defects as evident from FESEM and AFM analysis of machined surface. A nozzle distance of 30 mm, a flow rate of 50 ml/hr, and a dual-jet nozzle MQL configuration were identified as the optimum parameters for simultaneously reducing flank wear, surface roughness, cutting power, cutting temperature, and carbon emissions. This parametric condition demonstrated a precise machining process, attaining a minimal circularity error of 0.010 mm with a standard deviation of 0.012.