Development of finite element based model for performance evaluation of nano cutting fluids in minimum quantity lubrication

Abstract

Traditionally, cutting fluids are used to improve the performance of machining. However, due to the hazardous effects of these fluids on workers’ health and ecology, their usage has been often discouraged. As a solution, application of micro/nano cutting fluids in minimum quantity lubrication (MQL) has been proposed in the literature. Many of the works on MQL deal with experimental investigations, which are costly and cannot be generalised for other conditions. Works that apply numerical models like FEA to MQL are limited. In the present work, the performance of micro and nanofluids was compared. Two different solid lubricants — boric acid and molybdenum disulphide were dispersed in the coconut oil. Different machining parameters like cutting forces, cutting temperatures and surface roughness were studied while applying the formulated fluids in MQL. After observing the superior performance of nanofluids at the given cutting conditions, a finite element based model has been developed to predict forces and cutting temperatures. The model was compared with the experimental values and found capable of predicting the values within 8% accuracy. The validated model was used to predict the values for other cases.