Surface quality and efforts in milling of SAE 4340 steel with minimal amount of fluid

• Grant number: 14/03636-6
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• Start date: May 01, 2014
• End date: April 30, 2015
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Manoel Cleber de Sampaio Alves
• Grantee: Emanuele Schneider Callisaya
• Host Institution: Faculdade de Engenharia (FEG). Universidade Estadual Paulista (UNESP). Campus de Guaratinguetá. Guaratinguetá , SP, Brazil

Abstract

Many research and industry has tried reduce the use of fluid lubricants and coolants in machining processes without losing quality of the processed parts. This reduction is due to the high cost of maintenance and discard of these fluids, in addition to the severe damage they bring to the health of workers and the environment.Will analyze the surface quality and efforts in milling process of SAE 4340 steel using minimal amount of fluid (MQF) at different flow rates, comparing with conventional lubrication (abundant). Tests are performed with up-milling and down-milling with carbide tools, with and without coating.For different machining conditions will be checked the surface roughness the parts. Will be also analyzed the power consumed and tool wear. The project will be developed at the Laboratory for Studies of Machining at UNESP - Guaratinguetá using a CNC Machining Center Model DMU50ECO brand DMG DMG Ecoline Series. The steel used in this research will be the SAE 4340, used industrially in mechanical components that receive dynamic forces. The measurement of roughness is performed by Mahr profilometer mark MarSurf M300 model. The tool wear is measured with the stereoscopic Brand Mahr, MarVision model MM200. For the acquisition of power consumed, Hall effect sensors brand LEM model AT 50 B10 and a data acquisition system will be used. Appropriate statistical analysis (ANOVA, Tukey test, Taguchi method) will be made, seeking to understand the effects of MQL in milling of 4340 steel, and to correlate the output variables. As a result we seek to know the effects of MQF in up-milling and down-milling of SAE 4340 steel with carbide tools. As a result we intend to know the effects of MQF in concordant and discordant tangential milling SAE 4340 steel with carbide tools. (AU)