Machinability study of a390 hypereutectic al-si alloy using vegetable oil-based nanofluid in turning operation /
Nur Nadirah Binti Mohamad Raffi,
Machinability study of a390 hypereutectic al-si alloy using vegetable oil-based nanofluid in turning operation / Nur Nadirah Binti Mohamad Raffi - xviii, 132 pages : illustrations ; 30 cm. + 1 CD-COM.
Faculty of Manufacturing and Mechatronic Engineering Technology
Thesis (Master of Science) -- Universiti Malaysia Pahang - 2025
Includes bibliographical references
Surface finish greatly influences the performance and durability of engineering parts, with rough surfaces exhibiting higher wear rates and friction coefficients. This research investigates the machinability of hypereutectic aluminium silicon alloy A390 under Minimum Quantity Lubrication (MQL) conditions, optimizing machining parameters, evaluating tool wear, and assessing surface integrity. Full factorial design was employed to identify optimal parameters for turning A390, aiming to improve surface finish, reduce tool wear, and extend tool life. Experiments were conducted using a Romi C420 turning machine with a CVD TiN-coated cutting tool and a lubricant mixture consisting of 200 ml palm oil and 2 g nano-based silicon dioxide (SiO₂). Nine experimental runs were carried out with spindle speeds of 300 rev/min, 600 rev/min, and 900 rev/min, and feed rates of 0.1 mm/rev, 0.2 mm/rev, and 0.3 mm/rev. The depth of cut was fixed at 0.1 mm. Surface roughness was measured according to ISO 4287 standards, with the suggested range for internal engine parts being 0.4 to 1.6 μm. Results showed that spindle speed and feed rate significantly influenced surface roughness. The optimal combination of 900 rev/min and 0.1 mm/rev achieved the best surface finish of 0.277 μm, a 69% improvement compared to the roughest finish (1.73 μm in Run No. 9 with 900 rev/min and 0.3 mm/rev). Runs 7 and 9 were chosen as they provided the minimum and maximum surface roughness, respectively, to evaluate the range of surface finish achievable under different conditions. MQL effectively minimized tool wear, with flank wear being the predominant mechanism. For Run 7 (900 rev/min, 0.1 mm/rev), the tool life reached 0.2 mm wear at a cutting distance of 618 mm, while for Run 9 (900 rev/min, 0.3 mm/rev), the tool life reached 0.2 mm wear at a cutting distance of 33,433 mm. The predicted cutting distance to reach 0.3 mm wear for Run 7 is approximately 747 mm, representing an 18.9% increase from the experimental distance. For Run 9, the predicted cutting distance to reach 0.3 mm wear is 41,285 mm, a 23.5% increase from the experimental distance of 33,433 mm, based on the regression model and in line with ISO 3685 standards for tool life evaluation. Microhardness increased from 63.42 HV to 105.9 HV, primarily due to surface hardening and the formation of an aluminium oxide (Al₂O₃) layer during machining. ANOVA analysis confirmed that feed rate and spindle speed significantly affected surface roughness, with an inverse relationship to surface finish. In conclusion, MQL conditions, combined with optimized parameters, enhanced surface quality and extended tool life during the machining of A390. This study provides a framework for achieving minimal surface roughness, reduced tool wear, and improved microhardness in high-performance machining applications.
THE0010375 (Local)
Faculty of Manufacturing and Mechatronic Engineering Technology--Dissertations
Universities and colleges--Dissertations
Theses--Dissertations
Machinability study of a390 hypereutectic al-si alloy using vegetable oil-based nanofluid in turning operation / Nur Nadirah Binti Mohamad Raffi - xviii, 132 pages : illustrations ; 30 cm. + 1 CD-COM.
Faculty of Manufacturing and Mechatronic Engineering Technology
Thesis (Master of Science) -- Universiti Malaysia Pahang - 2025
Includes bibliographical references
Surface finish greatly influences the performance and durability of engineering parts, with rough surfaces exhibiting higher wear rates and friction coefficients. This research investigates the machinability of hypereutectic aluminium silicon alloy A390 under Minimum Quantity Lubrication (MQL) conditions, optimizing machining parameters, evaluating tool wear, and assessing surface integrity. Full factorial design was employed to identify optimal parameters for turning A390, aiming to improve surface finish, reduce tool wear, and extend tool life. Experiments were conducted using a Romi C420 turning machine with a CVD TiN-coated cutting tool and a lubricant mixture consisting of 200 ml palm oil and 2 g nano-based silicon dioxide (SiO₂). Nine experimental runs were carried out with spindle speeds of 300 rev/min, 600 rev/min, and 900 rev/min, and feed rates of 0.1 mm/rev, 0.2 mm/rev, and 0.3 mm/rev. The depth of cut was fixed at 0.1 mm. Surface roughness was measured according to ISO 4287 standards, with the suggested range for internal engine parts being 0.4 to 1.6 μm. Results showed that spindle speed and feed rate significantly influenced surface roughness. The optimal combination of 900 rev/min and 0.1 mm/rev achieved the best surface finish of 0.277 μm, a 69% improvement compared to the roughest finish (1.73 μm in Run No. 9 with 900 rev/min and 0.3 mm/rev). Runs 7 and 9 were chosen as they provided the minimum and maximum surface roughness, respectively, to evaluate the range of surface finish achievable under different conditions. MQL effectively minimized tool wear, with flank wear being the predominant mechanism. For Run 7 (900 rev/min, 0.1 mm/rev), the tool life reached 0.2 mm wear at a cutting distance of 618 mm, while for Run 9 (900 rev/min, 0.3 mm/rev), the tool life reached 0.2 mm wear at a cutting distance of 33,433 mm. The predicted cutting distance to reach 0.3 mm wear for Run 7 is approximately 747 mm, representing an 18.9% increase from the experimental distance. For Run 9, the predicted cutting distance to reach 0.3 mm wear is 41,285 mm, a 23.5% increase from the experimental distance of 33,433 mm, based on the regression model and in line with ISO 3685 standards for tool life evaluation. Microhardness increased from 63.42 HV to 105.9 HV, primarily due to surface hardening and the formation of an aluminium oxide (Al₂O₃) layer during machining. ANOVA analysis confirmed that feed rate and spindle speed significantly affected surface roughness, with an inverse relationship to surface finish. In conclusion, MQL conditions, combined with optimized parameters, enhanced surface quality and extended tool life during the machining of A390. This study provides a framework for achieving minimal surface roughness, reduced tool wear, and improved microhardness in high-performance machining applications.
THE0010375 (Local)
Faculty of Manufacturing and Mechatronic Engineering Technology--Dissertations
Universities and colleges--Dissertations
Theses--Dissertations