A Taguchi Method Approach to Optimizing Graphite and Boric Acid Powder Effects on Tool Wear and Surface Roughness

In recent times, there has been a noticeable emergence of solid lubricant-assisted machining as an innovative trend, displaying promising potential to supplant traditional cutting fluids. However, concerns have arisen regarding its comparative performance in relation to conventional wet and dry machining methods. Furthermore, uncertainties persist concerning the most suitable lubricant material for this specific application. This study is driven by the objective of discerning the optimal configuration of four critical control factors: spindle speed, feed rate, types of solid lubricant, and their respective ratios. The goal is to understand their collective influence on tool wear and surface roughness during milling operations. By leveraging Taguchi experimental design and ANOVA analyses, the substantial impacts of these primary factors on the optimization of tool wear and surface roughness are elucidated. The results show that the most effective arrangement for minimizing tool wear entails employing high spindle speeds and feed rates, coupled with a lubricant mixture that combines boric acid and graphite in a high ratio. In the context of minimizing surface roughness, the optimal combination calls for moderate spindle speeds and feed rates, alongside a higher ratio of the boric acid and graphite lubricant mixture. This research convincingly shows the pivotal role played by the type and ratio of solid lubricants in enhancing overall machining performance.