MACHINING PERFORMANCE ANALYSIS IN TURNING OF GRAY CAST IRON WITH SPECIALIZED DESIGNED COOLANT NOZZLE

Abstract

In manufacturing process coolant technique is one of the most important phenomena in machining. In our research work we have tried to optimize the use of high-pressure coolant on the principal and auxiliary cutting edge to improve the machining performance in turning of gray cast iron. We used synthetic oil as coolant and we used nozzle valves in such a way that the coolant came out as mist with high pressure. As when the coolant is applied as mist it eventually spread all over the manufacturing tool and reduce the temperature. Using of mist made the process more cost efficient too. On other hand it decreased the wastage of coolant. Because when we apply coolant with a flood system, system released more coolant than we actually need, which is totally wastage of coolant. Ultimately, we observed the tool life and surface roughness of the workpiece after machining we analyzed the results using RSM in design expert 13 software. We got range of some specific values of cutting speed and feed rate for optimum values of surface roughness and temperature by analyzing the 3D graphs. Finally, we analyzed that using the double nozzle coolant technique in our machining we got better surface roughness and it minimized the generated temperature between the cutting tool and the work piece than the single nozzle coolant technique. Our research will have more future scopes to work with like we can further work with the characteristics of chip formation and chip thickness.