EXPERIMENTAL STUDY OF NANO-LUBRICANT ON TEMPERATURE REDUCTION AND DISTRIBUTION DURING MACHINING OF AL-SI-MGCOMPOSITE USING DEFORM 3D FINITE ELEMENT METHOD

The temperature reduction process is a vital part of the manufacturing process. High-temperature generation during machining operation leads to thermal deformation on the developed component, affecting the operation life span of the component. The computer numerical machining process is one of the recent technology employed for the automatic manufacturing process. These operations are plagued with temperature during the machining of transforming hard raw materials to replace mechanical parts. Therefore, cutting fluid for lubrication and as cooling agents has become a necessary part of this process to reduce cost and manufacturing time. Thus, this study investigated the effect of mineral oil-based-Multi-walled carbon nanofluid (MWCNTs) compared to pure mineral oil in the turning of aluminum-silicon magnesium metal matrix composite (AlSiMg) on temperature reduction and distribution. The nanofluid was prepared with 0.4g of MWCNT to 1 liter of mineral oil. The study employed the energy dispersive spectrometer to obtain the chemical composition of the developed nanofluid. The turning experiment was done using Taguchi L9 orthogonal array to obtain the best possible results. Furthermore, Finite element software DEFORM 3D v11.0 using a lagrangian incremental approach was employed to simulate chip formation and temperature distribution on the workpiece and to study the effects of the machining parameters on the temperature distribution. The experiment results showed a significant reduction of 11.9% in temperature when machining with nanofluid compared to pure mineral oil. The simulation results showed that as the cutting speed and feed rate increase, the temperature increases. The minimum temperature via the DEFORM 3D Finite Element Model simulation was achieved at spindle speed 870 rpm, feed rate 2 mm/rev, and depth-of-cut 1 mm. In conclusion, the study recommends that the manufacturing industry employ the optimized machining parameters during the turning of AlSiMg metal matrix composite for a sustainable machining process.