Energy Efficiency in Alloyed Steel Milling Process with Nano-Fluid Based Cooling and Lubrication

In this study, the energy efficiency of the workpiece material removal process in the cutting zone during end milling, was analysed.End mill cutter with exchangeable coated inserts was used.Hard-to-machine and high-alloyed tool steel X210CrVMo2-1 was used as the workpiece material.The experimental research and analysing included two cases of cutting zone cooling and lubrication: first with a standard emulsion (water and oil), and second with nano-fluid.The nano-fluid is made as a dispersion of molybdenum disulphide nanoparticles in a standard emulsion.Nano-fluid, as a cooling and lubricating agent, was dosed by flooding technique.A standard system on the tool machine was used there.Feed per tooth, cutting speed, and depth of cut are selected as controlled cutting process parameters.For the experimental research, Taguchi's experimental plan L9 was used, which is given nine combinations of input cutting process parameters values.The same set of cutting process parameter combinations was used for both cooling and lubrication case.Based on the measured cutting forces, the cutting power and cutting energy values were recalculated and analysed.As an indicator of the process productivity, material removal rate is also included in the analysis, and consequently, specific cutting energy was analysed as an additional indicator of energy efficiency.Statistical analysis by ANOVA, development of adequate energy efficiency indicators models, and process parameters optimisation were also performed.Based on developed model, optimal values of the input cutting process parameters, fz = 0.172 mm/tooth, vc = 109 m/min, and ap = 10 mm were obtained.