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An Experimental Investigation on the Effects of MQL Method on Grinding of Nickel Based Superalloy 738 (Inconel 738)

Khazali, Mohsen | 2016

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 48936 (08)
  4. University: Sharif University of Technology
  5. Department: Mechanical Engineering
  6. Advisor(s): Akbari, Javad
  7. Abstract:
  8. The issues relevant to lubricants in industry, construction and production processes such as machining and grinding have been recently taken into serious consideration. Unlike the positive effects of applying lubricants on machining forces, chip formation, thermal defects which lead to force reduction, lower power consumption and surface quality improvement, its conventional usage has adverse effects such as environmental problems, high cost of high volume lubricant application as well as recycling problems. Therefore, attention was drawn toward chip removal under dry or near dry conditions and as thermal defects such as surface burning is important particularly in grinding, grinding under near dry condition or minimum quantity lubrication would be more ideal.As gas turbine blades should have acceptable function under special temperature and fatigue forces, they are made of super alloys and one of the most applicable is Inconel 738. In this work, the usage possibility of minimum quantity lubrication in grinding super alloy Inconel 738 has been studied empirically to reach improved grinding and lubricating conditions. For reaching this purpose, based on Taguchi design of experiment method grinding variables were set in three levels and lubrications were set in six levels in order to compare conventional, dry and MQL methods. Studies have shown that in grinding this material by MQL method we can obtain the results very close to conventional mode in terms of force and surface roughness even having better surface quality. Results in MQL method by considering various oils with different viscosities show that Behzist 6046 and Canola herbal-based oil are the best replacement of conventional method in terms of force reduction and surface roughness. As a result, it reduces environmental problems derived from overusing of lubricants. In fact we can see 50% force reduction in the case of using MQL with Behzist 6046 and there is just 30% difference between surface roughness results of conventional lubrication (which has the lowest surface roughness) and using MQL system with Behzist 6043
  9. Keywords:
  10. Gas Turbine Blades ; Taguchi Method ; Grinding ; Minimum Quantity Lubrication ; Lubrication ; Inconel 738 Superalloy

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