Performance of Al₂O₃ nanofluids in minimum quantity lubrication in hard milling of 60Si₂Mn steel using cemented carbide tools

Abstract

In this article, an attempt has been made to explore the potential performance of Al 2 O 3 nanoparticle-based cutting fluid in hard milling of hardened 60Si 2 Mn steel (50-52 HRC) under different minimum quantity lubrication conditions. The comparison of hard milling under minimum quantity lubrication conditions is done between pure cutting fluids and nanofluids (in terms of surface roughness, cutting force, tool wear, and tool life). Hard milling under minimum quantity lubrication conditions with nanofluid Al 2 O 3 of 0.5% volume has shown superior results. The improvement in tool life almost 177%-230% (depending on the type of nanofluid) and the reduction in surface roughness and cutting forces almost 35%-60% have been observed under minimum quantity lubrication with Al 2 O 3 nanofluids due to better tribological behavior as well as cooling and lubricating effects. The most outstanding result is that the uncoated cemented carbide insert can be effectively used in machining high-hardness steels (.50 HRC) while maintaining long tool life and good surface integrity (R a = 0.08-0.35 mm; R z = 0.5-2.0 mm, equivalent to finish grinding) rather than using the costlier tools like coated carbide, ceramic, and (P)CBN. Therefore, using hard nanoparticle-reinforced cutting fluid under minimum quantity lubrication conditions in practical manufacturing becomes very promising.

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

“…It can be explained that the ignition temperature of soybean oil is lower than that of water-based emulsion. Therefore, the high heat generated from hard turning makes the lubricating character of soybean oil less effective, and this observation is suitable with previous studies [12,19,34].…”

“…Duc, T.M. et al [19] studied the performance of Al 2 O 3 nanofluids in MQL hard milling using carbide tools. The experimental results revealed the decrease of friction coefficient, cutting forces and tool wear due to the effectiveness of Al 2 O 3 nanofluids, which led to the improvement of cutting performance, surface quality, and tool life.…”

Nanofluid as an Alternative Coolant in Machining: A Review

“…Vázquez et al, mentioned that by adding the nanoparticles into the conventional cutting fluid, their thermal properties enhanced and increase the tool life [44]. Minh et al, stated that the main reason for the tool life prolonged is due to the oil mist and the number of nanoparticles formed on flank face [45]. The formed oil mist and nanoparticles in the cutting zone increases to create "roller effect" which eventually reduce the cutting force and tool wear.…”

“…Tool life enhancement [44] CuO nanoparticles with mineral oil Increase the service life of the cutting tool up to 604% [45] Al2O3 with soybean oil Increase almost 177% of the tool life than base fluid [46] Al2O3/MWCNT hybrid nano fluid with vegetable oil Improved the tool life much more better than base fluid and single nanofluid (Al2O3) [47] TiO2 with deionized water 70% more tool life than water [30] Al2O3 with carbon nanotube (CNT) in vegetable oil 23% enhancement [48] Al2O3 with vegetable oil 23.5% enhancement in tool life [49] Graphene with vegetable oil 178-190% of tool life enhancement [50] Ethylene glycol based TiO2 Tool life is 54.9 minutes.…”

Evaluation of graphene based nano fluids with minimum quantity lubrication in turning of AISI D3 steel

“…The authors confirmed that surface roughness, cutting temperature and residual stress were reduced compared with flood cutting. Minh et al [35] noticed during milling of 60Si 2 Mn steel with Al 2 O 3 nano fluids under MQL condition that 0.5% volume of Al 2 O 3 nano particles reduced the cutting force, surface roughness and tool wear compared to normal cooling system. Gupta et al [36] executed several replacements under dry machining, nitrogen cooling, nitrogen with minimum quantity lubrication and ranque-Hilsch vortex tube in turning AL 7075-T6 alloy.…”