The objective of this research work is to synthesize Alumina@Copper, core@shell nanoparticles suspended nanofluid coolant, possessing high thermal conductivity. The Alumina@Copper nanoparticles were synthesized by two step chemical process. The methodology used to synthesize core@shell nanoparticles includes the synthesis of base alumina nanoparticles by sol-gel method in first step, which was coated with a thin shell of copper using electroless plating technique. The study investigates thermal conductivity enhancement of prepared nanofluid coolant, upon suspension of these nanoparticles for the selected volume of Strub Vulcan Futura coolant oil. Nanoparticles addition to the coolant oil was 0.025 % to 0.3 % by weight. Results indicated that, alumina@copper nanoparticles addition enhanced the thermal conductivity value up to 23.39 %. Results were validated using Hamilton and Crosser (HC) theoretical model assuming nanoparticles to be spherical. An empirical correction factor was applied for HC model which fits the thermal conductivity values to justify the deviation. The findings of this research may serve for faster heat dissipation during any metal cutting operation, since the synthesized nanofluid coolant possesses enhanced thermal conductivity.
Present day industries are focusing upon finding various methods and techniques to implement sustainable manufacturing, which is ‘the need of the hour’. With increase in global competition, industries are striving hard to reduce the machining costs, which is a major contributor for ‘manufacturing cost per part’, in an industry. Conventional method of using large quantity of coolant/cutting fluids in several liters per hour, to cool machining zone is causing enormous concern. Strict Government regulations are necessitating industries to replace flood-coolant assisted machining by new techniques like ‘Minimum Quantity lubrication’ (MQL) coolant supply technique. The present work deals with investigating the effect of varying nozzle angle and air-flow rate during MQL assisted surface milling of aerospace aluminum Al7075-T6 alloy, using uncoated carbide tool. Three methods of coolant supply namely Dry, MQL and nanofluid MQL (nano particles us pended oil with MQL) are experimented. Cutting speed [150m/min, 208m/min, 264 m/min], feed rate [95 mm/min, 110 mm/min, 125 mm/min] and depth of cut [0.5 mm, 1.3 mm, 2 mm] are chosen as process variables. Two nozzle angles 25°C and 500, with 1.5 kg/cm2 and 3 kg/cm2 air flow rates were investigated. Best results were obtained for air flow rate of 1.5kg/cm2. Optimumnozzleangle was found to be 25°C. To obtain lowest temperature and reduced heat generation, nanofluid MQL machining is a feasible option. With regards to MQL technique, for obtaining better surface finish with reduced surface roughness of the work piece (Al7075-T6), nanofluid MQL technique is best.
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