Effects of extreme pressure and anti-wear additives on surface topography and tool wear during MQCL turning of AISI 1045 steel | Journal of Mechanical Science and Technology
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Effects of extreme pressure and anti-wear additives on surface topography and tool wear during MQCL turning of AISI 1045 steel

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Abstract

The paper presents an original study of the influence of extreme pressure and anti-wear (EP/AW) additives on the surface topography of double-phase steel during turning with different cooling media and variable flow rates. The obtained surface topographies were compared using frequency and fractal analyses for dry, minimum quantity cooling lubrication (MQCL), and MQCL + EP/AW methods. Results showed that the addition of phosphate ester-based additives to an active medium caused the formation of tribofilm on the tool-chip interface and thus a change in the lubricating properties by reducing friction. The tool wear and the formation of the thin-layered tribofilm were also incorporated. The application of the MQCL method with the EP/AW additives led to a decrease in particular surface topography parameters from 8 % to 38 % in comparison with the effects of dry cutting and from 6 % to 35 % in comparison with the effects of machining under MQCL conditions. An exception was the result obtained for the surface roughness height parameter Sp, which was higher than that obtained after the MQCL + EP/AW process for the lowest investigated feed per revolution f = 0.1 mm/rev. This observation was correlated with the uneven formation of the tribofilm on the machined surface. The phosphate ester-based additive used in the MQCL + EP/AW method contributed to achieving tool wear that was less than that obtained by the processes conducted under dry and MQCL conditions.

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana Street, 65-516, Zielona Gora, Poland

    Radoslaw W. Maruda

  2. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758, Opole, Poland

    Grzegorz M. Krolczyk, Krzysztof Zak & Piotr Nieslony

  3. Faculty of Mechanical Engineering and Management, Poznan University of Technology, 3 Piotrowo Street, 60-965, Poznan, Poland

    Szymon Wojciechowski

  4. Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, al. Powstancow Warszawy 8, 35-959, Rzeszow, Poland

    Witold Habrat

Authors
  1. Radoslaw W. Maruda
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  2. Grzegorz M. Krolczyk
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  3. Szymon Wojciechowski
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  4. Krzysztof Zak
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  5. Witold Habrat
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  6. Piotr Nieslony
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Corresponding author

Correspondence to Grzegorz M. Krolczyk.

Additional information

Recommended by Associate Editor Sang-Hee Yoon

Radoslaw Maruda graduated from the Technical University of Zielona Góra. He has been working at the Faculty of Mechanical Engineering, University of Zielona Góra since his graduation. His current research focuses on the ecological cooling (MQL and MQCL methods) of cutting zones.

Grzegorz Krolczyk is a Professor at the Opole University of Technology (OUTech). He is an Originator and Project Manager of the new Surface Integrity Laboratory of OUTech. He is author and coauthor of 136 scientific publications (62 JCR papers) and nearly 29 studies and industrial applications. His main scientific directions are analysis and improvement of manufacturing processes.

Szymon Wojciechowski graduated from the Poznan University of Technology. He works at the Faculty of Mechanical Engineering and Management, Poznan University of Technology. His scientific interests concentrate on modeling and investigating forces in the curvilinear milling of hard-to-machine materials.

Krzysztof Zak obtained his Ph.D. in 2008 in mechanical engineering from OUTech. He is currently an Assistant Professor in the Department of Manufacturing Engineering and Production Automation. He is author and coauthor of many articles published in reputable journals. He specializes in machining and surface engineering.

Witold Habrat received his Ph.D. from the Rzeszow University of Technology in 2006. He works at the Faculty of Mechanical Engineering and Aeronautics in this university. His research interests include modeling of machining of difficult- to-cut materials, high-pressure cooling, laser-assisted machining, optimization of machining processes, and analysis of surface layer states.

Piotr Nieslony is a Professor at OUTech and the Head of the Department of Manufacturing Engineering and Production Automation at the Faculty of Mechanical Engineering. His research fields include finite element analysis of machining processes, tribology, analysis of tool wear, tool coatings, optimization procedures of technological processes, and surface structure analysis.

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Maruda, R.W., Krolczyk, G.M., Wojciechowski, S. et al. Effects of extreme pressure and anti-wear additives on surface topography and tool wear during MQCL turning of AISI 1045 steel. J Mech Sci Technol 32, 1585–1591 (2018). https://doi.org/10.1007/s12206-018-0313-7

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  • DOI: https://doi.org/10.1007/s12206-018-0313-7

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