High-speed machining processes are significantly affected by the accumulation of heat generated by friction in the cutting zone, leading to reduced tool life and poor quality of the machined product. The use of cutting fluids helps to draw the heat out of the area, owing to their cooling and lubricating properties. However, conventional cutting fluid usage leads to considerable damage to human health and the environment, in addition to increasing overall manufacturing costs. In recent years, minimum quantity lubrication (MQL) has been used as an alternative lubricating strategy, as it significantly reduces cutting fluid consumption and eliminates coolant treatment/disposal needs, thereby reducing operational costs. In this study, we investigated microstructural surface finishing and heat generation during the high-speed cutting process of 2219 aluminum alloy using an MQL nanofluid. 2219 aluminum alloy offers an enhanced strength-to-weight ratio and high fracture toughness and is commonly used in a wide range of aerospace and other high-temperature applications. However, there is no relevant literature on MQL-based high-speed machining of these materials. In this study, we examined flood coolant and five different MQL nanofluids made by synthesizing 0.2% to 2% concentrations of Al2O3 nanoparticles into ultra-food-grade mineral oil. The study results reveal the chemistry between the MQL of choice and the corresponding surface finishing, showing that the MQL nanofluid with a 0.5% concentration of nanoparticles achieved the most optimal machining result. Furthermore, increasing the nanoparticle concentration does result in any further improvement in the machining result. We also found that adding a 0.5% concentration of nanoparticles to the coolant helped to reduce the temperature at the workpiece–tool interface, obtaining a good surface finish.
The lubricant choice is a critical factor in the high-speed machining process, and it can impact the machining surface quality and also the ultimate material properties. This paper investigates the microstructural surface finishing and heat generated during the high-speed cutting process (machining speed 3800 RPM) of 2219 aluminum alloy. The study examines flood coolant and five different nanofluids made by synthesizing 0.2–2% concentration of Al2O3 nanoparticles into ultra-food-grade mineral oil utilizing nanoparticle-enhanced minimum quantity lubrication (MQL) technique. In the MQL method, unlike the current known cooling fluid systems, the nanofluid provides a thin lubricant film that leads the heat created by friction to be transmitted to the chips and exits the interface. Also, the small amount of lubricant used for MQL makes this technique more environmentally friendly. The study revealed the chemistry between the MQL of choice and the corresponding surface finishing. As a result, the nanofluid with a 0.5% concentration of nanoparticles has the most optimal machining result. Furthermore, increasing nanoparticle concentration does not indicate any further improvement in the result. The results of this study could be instrumental to developing environmental-friendly machining solutions for aluminum alloys at commercial scales.
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