A review of sustainable hybrid lubrication (Cryo-MQL) techniques in machining processes

Yaqoob, Saima; Ghani, Jaharah A.; Juri, Afifah Z.; Muhamad, Shalina Sheik; Haron, Che Hassan Che; Jouini, Nabil

doi:10.1007/s00170-024-13135-4

Cited by 2 publications

(2 citation statements)

References 107 publications

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“…Additionally, rising manufacturing costs and regulations are forcing the industry to seek alternatives to conventional cooling lubrication methods. These alternatives include cryogenic cooling, gaseous lubrication, dry machining, environmentally friendly MWFs, MQL, and their combinations (Cryo-MQL) [4]. These methods fulfill the requirements of the three pillars of sustainability (as shown in Figure 1), namely, social, economic, and environmental [5].…”

Section: Introductionmentioning

confidence: 99%

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Effect of lubricated CO2 on grinding of AISI 4140 steel

Santhosh,

Hoier,

Pušavec

et al. 2024

Preprint

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This paper explores the potential of using lubricated liquid carbon dioxide (LCO2) in grinding processes. Cooling and lubrication are critical in grinding, with conventional flood cooling effectively reducing temperatures and improving surface integrity. However, conventional fluids often contain petroleum-based substances, posing a challenge to fossil-free production. A novel approach involves the use of premixed LCO2 and oil via single-channel minimum quantity lubrication (MQL), which has shown promise in machining with geometrically defined cutting edges but is under-researched in grinding.To fill this gap, we conducted an experimental study on the grindability of AISI 4140 steel, evaluating different cooling/lubrication methods and their effects on surface roughness, residual stresses, microhardness, grinding forces and specific energy. The results indicate that LCO2 + MQL can achieve surface roughness and microhardness comparable to conventional flood cooling, especially for less aggressive finish grinding. However, higher tensile stresses in rough grinding suggest that cooling may be inadequate. Optimisation of nozzle design, orientation and flow rate can improve cooling efficiency and reduce residual tensile stresses. This study shows that LCO2 + MQL is a viable, sustainable alternative to conventional flood cooling, capable of maintaining the required surface integrity in grinding operations.

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Section: Introductionmentioning

confidence: 99%

“…[27][28][29][30][20] and the formation of boundary lubrication by MQL[31] may be responsible for comparable surface finish.…”

mentioning

confidence: 99%

Effect of lubricated CO2 on grinding of AISI 4140 steel

Santhosh,

Hoier,

Pušavec

et al. 2024

Preprint

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Performance Evaluation of PVD and CVD Multilayer-Coated Tools in Machining High-Strength Steel

Yaqoob,

Ghani,

Jouini

et al. 2024

Coatings

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To curtail the negative effects of traditional flood machining, dry cutting using carbide tools has emerged as a prominent alternative for manufacturers, owing to its low cost and phenomenal surface qualities. In line with this view, high-speed machining of high-strength AISI 4340 alloy steel was carried out using multilayer Al2O3/TiCN-CVD and TiAlN/AlCrN-PVD carbide tools in a dry environment. The experimental scheme was adopted, as per Taguchi’s L18 orthogonal array, to investigate the two most crucial machinability aspects, namely tool life and surface roughness. An analysis of variance (ANOVA) was performed on the obtained data, and it was inferred that the feed rate exhibited the strongest effects on both the tool life and surface roughness, with corresponding percentage contributions of 46.22% and 68.96%, respectively. The longest tool lives of 14.75 min and 10.08 min were obtained at a low cutting speed and feed rate for CVD and PVD tools, respectively. However, the lowest surface roughness of 0.276 µm and 0.307 µm was achieved at a high cutting speed and low feed rate for PVD and CVD tools, respectively. The evolution of tool wear, studied through the microscopic images of the worn tools, revealed that a high cutting speed and feed rate accelerated the flank wear for both types of tools. Nevertheless, the CVD tool exhibited better results due to the thick and effective Al2O3/TiCN coating layer, which protected the carbide substrate against thermal–mechanical loads. Moreover, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) performed on the worn tools revealed that adhesion, oxidation, diffusion, and abrasion were the main wear mechanisms for both types of tools.

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A review of sustainable hybrid lubrication (Cryo-MQL) techniques in machining processes

Cited by 2 publications

References 107 publications

Effect of lubricated CO2 on grinding of AISI 4140 steel

Effect of lubricated CO2 on grinding of AISI 4140 steel

Performance Evaluation of PVD and CVD Multilayer-Coated Tools in Machining High-Strength Steel

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