Investigation of Machining Performance of MQL and MQCL Hard Turning Using Nano Cutting Fluids

Abstract

Cutting fluids used in the metal machining industry have exerted serious impacts on the environment and human health. In addition, the very high cutting heat and forces in machining-hardened steels have been a growing concern in the metal cutting field. Hence, new, eco-friendly cooling and lubricating techniques are necessary to study and develop. Minimum quantity lubrication (MQL) and minimum quantity cooling lubrication (MQCL) using nano cutting fluids have been proven as alternative solutions for machining difficult-to cut materials while retaining an environmentally friendly characteristic. Accordingly, this paper aims to analyze and evaluate the hard turning efficiency of 90CrSi (60 ÷ 62 HRC) steel using MQL and MQCL conditions, using Al2O3 and MoS2 nano cutting fluids. The 2k-p experimental design and analysis of variance (ANOVA) were used to study the influence of input parameters including fluid type, lubrication method, nanoparticle type, nanoparticle concentration, cutting speed and feed rate on surface roughness. The obtained results showed that the machinability of CNMG120404 TM T9125 carbide tools was improved and the highest machinable hardness was increased from 35 HRC to 60 ÷ 62 HRC (rising by approximately 71.4 ÷ 77.1%) by using the nanofluid MQL and MQCL methods. Furthermore, MQCL gives better performance than MQL, and the Al2O3 nanofluid exhibits the better result in terms of surface roughness values than the MoS2 nanofluid. Feed rate displays the strongest influence on surface roughness, while fluid type, nanoparticle concentration and cutting speed show low impacts. From these results, technical guidance will be provided for further studies using Al2O3 and MoS2 nano cutting fluids for MQL and MQCL methods, as well as their application in machining practice.

Parametric optimization to establish eco-friendly nanofluid minimum quantity lubrication (NMQL) practice for turning superalloy Inconel 718

“…But many cutting fluids have harmful chemical components that are dangerous or could cause machinist health risks and ecological issues. Additionally, due to economic pressures, government regulations and rigorous environmental laws, investigators are searching for alternative ways to lessen the use of cutting fluids in machining operations (Tuan et al , 2022). Dry machining in the absence of any cutting fluid is currently receiving more attention due to its success in green machining situations (Şirin, 2023).…”

A review on minimum quantity lubrication (MQL) assisted machining processes using mono and hybrid nanofluids

“…On the other side, many cutting fluids contain unsafe or potentially damaging chemical constituents (Park et al, 2014;Cetin et al, 2011). Moreover, with growing awareness of environmental and health issues, government strict environmental regulations and economic pressures, industries and researchers are seeking alternative methods for reducing the consumption of cutting fluids in metal cutting applications (Tuan et al, 2022;Khanna et al, 2021;Boswell et al, 2017;Rubio et al, 2015;Kajaria et al, 2012;Dhar et al, 2006). Dry machining (without cutting fluid) is now gaining attention because it is meeting with success concerning the ecological machining environment (Ibrahim et al, 2022;Hamran et al, 2020).…”

Experimental investigation and optimization of hybrid turning of Ti6Al7Nb alloy under nanofluid based MQL by TOPSIS method

“…Multiple types of nanoparticles, such as Al 2 O 3 [29], MoS 2 [30], CuO [31], zinc oxide (ZnO) [32], carbon nanotube [33], and graphene [26] etc. have been employed for the purpose of nanofluid preparation and subsequent examination of their effects.…”