Performance Evaluation of MQL Parameters Using Al2O3 and MoS2 Nanofluids in Hard Turning 90CrSi Steel

Abstract

Hard machining has gained much attention to be an alternative solution for many traditional finish grinding operations due to high productivity, ease to adapt to complex part contours, the elimination of cutting fluids, good surface quality, and the reduction of machine tool investment. However, the enormous amount of heat generated from the cutting zone always requires the high-grade inserts and limits the cutting conditions. The MQL technique with nanofluids assisted for hard machining helps to improve the cutting performance while ensuring environmentally friendly characteristics. This paper focuses on the development of MQL technique by adding Al2O3 and MoS2 nanoparticles to the base fluids (soybean oil and water-based emulsion) for the hard turning of 90CrSi steel (60÷62 HRC). The analysis of variance (ANOVA) is used to evaluate the performance of MQL parameters in terms of cutting forces and surface roughness. The study reveals that a better performance of coated carbide inserts is observed by using MQL with Al2O3 and MoS2 nanofluids. In addition, the fluid type, nanoparticles and nanoparticle concentration have a strong effect on cutting performance. The interaction influence among the investigated variables is also studied in order to provide the technical guides for further studies using Al2O3 and MoS2 nanofluids.

Evaluation of minimum quantity lubrication and minimum quantity cooling lubrication performance in hard drilling of Hardox 500 steel using Al2O3 nanofluid

“…However, metal cutting processes encounter the challenge when performing with normal cutting tools and dry condition, which limits the productivity and increase the machining cost. Recently, NFMQL [23][24][25][26] and minimum quantity cooling lubrication (MQCL) [27][28][29][30][31] have been considered the promising solutions to overcome the low cooling performance, the main drawback of the MQL technique. They give out the novel alternative machining techniques assisted to difficult-tomachine materials, but almost all the studies on machining under MQCL condition used emulsion-based fluid possessing the cooling property assisted to the MQL method.…”

MQL Strategies Applied in Ti-6Al-4V Alloy Milling—Comparative Analysis between Experimental Design and Artificial Neural Networks

“…The type of base fluid has a strong effect on the components of the cutting force. Consequently, the force is significantly reduced [ 1 ]. For the roughness parameter, the main factors that influence it are the feed rate, the cutting speed, the depth of cut, the vibrations of the cutting tools, the lubricant conditions, and the tool specifications [ 19 ].…”

“…Machining processes, such as turning, boring, drilling, and milling, are some of the most important techniques used in industries [ 1 ]. In these processes, the material is separated from the original body by the chips, creating a new shape, and it is estimated that it contributes to approximately 5% of the GDP in developed countries [ 2 ].…”

Novel Uses of Al2O3/Mos2 Hybrid Nanofluid in MQCL Hard Milling of Hardox 500 Steel

“…There have been a number of publications showing the effectiveness of the application of hybrid nanofluids in machining, but mainly focused on the turning process with MQL technique [31][32][33], while the studies on hard milling process with minimum quantity cooling lubrication (MQCL) technique is very little information [34][35][36]. Therefore, the author conducted a study on the effect of Al 2 O 3 /MoS 2 hybrid nanofluid on surface roughness in hard milling of 500 Hardox steel under MQCL condition.…”