Abstract

The manufacturing sector is among the fastest-growing in today's industrialized world. Manufacturers are concerned about increasing their competitiveness and profitability. Increasing the efficiency and sustainability of manufacturing processes is one way to improve productivity and improve profit margins. Learning about cutting conditions and how they affect machined surfaces and tool life can help improve productivity. Nowadays, the goal is not just to increase productivity but also to make processes more environmentally friendly and cleaner. This research aims to analyze the machinability of difficult-to-cut magnesium alloys through different cooling and lubrication strategies and their impact on the environment. This study conducted controlled machining tests with dry and vegetable oil mist cutting settings to measure surface roughness, tool contact length, chip morphology, and flank wear. The present study provides insight into the cutting performance of coated carbide tools. To improve the machinability of magnesium alloys, the study also investigated tool wear mechanisms, surface roughness, and primary and secondary components of machining, such as effective shear angle, compression ratio, and coefficient of friction. In this study, we found that minimum quantity lubrication (MQL) performed well under various speed ranges for coated tools. Cutting speed and feed rate correlated closely with tool wear, surface roughness, and other output response parameters. MQL-based systems offer great potential to improve the machinability of magnesium alloys, and they should be explored further.

Library of Congress Subject Headings

Lubrication and lubricants--Testing; Magnesium alloys; Hard materials--Machining

Publication Date

4-2022

Document Type

Thesis

Student Type

Graduate

Degree Name

Mechanical Engineering (MS)

Department, Program, or Center

Mechanical Engineering (KGCOE)

Advisor

Salman Pervaiz

Advisor/Committee Member

Wael Abdel Samad

Advisor/Committee Member

Dua Weraikat

Campus

RIT – Main Campus

Plan Codes

MECE-MS

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