Effect of using sustainable Lubricants on Surface Roughness and Energy Consumption during Milling of Aerospace Alloys /
Muhammad Ahsan Pervaiz Khan
- 110p. Soft Copy 30cm
The manufacturing sector is increasingly seeking higher production rates, resulting in a greater demand for finished or near-finished components, where surface roughness serves as a crucial indicator of surface quality in machined parts. Alongside this, there is a robust effort to reduce energy consumption during machining processes, thereby lessening the carbon footprint associated with manufacturing. Milling is one of the most widely used cutting processes in the industry; however, the conventional lubricants used have raised significant health concerns. This study investigates the impact of sustainable lubricants, specifically sunflower oil, on surface roughness and energy consumption during the milling of aerospace alloys. In the present research, the machining parameters were varied using the Taguchi L9 array design of experiments, and their influence on the response parameters, including specific cutting energy and surface finish was ascertained under different conditions: dry, with conventional cutting oil, and using sustainable sunflower oil. Our analysis of variance revealed that feed per tooth (fz) was the most influential parameter, accounting for 55.46% and 65.69% of the variation in surface roughness and specific cutting energy, respectively. Notably, results indicated that sunflower oil as a lubricant not only decreased energy consumption but also offered an environmentally friendly alternative. Validation of the experimental design was achieved through confirmatory tests conducted under both optimal and suboptimal conditions, supporting the srobustness of our findings.