Novel uses of SiO2 nanolubrication in end milling of medium carbon steel for higher compressive residual stress measured by high-energy X-ray diffraction data

Abstract

Milling is a machining process that removes any desired material from the surface by using relative motion between a work piece and a rotating cutter where the cutting tool intermittently enters and leaves the work piece. The milling process operates in two modes, namely, conventional (up) mode and climb (down) mode. Both modes are known for their significant effects on surface integrity due to the entering movement of the cutting tool and the formation of the chips during cutting process. Use of flood lubrication can improve the residual stress and surface quality of the component. It controls the temperature in cutting zone, reduces the power required, washes away chips, and reduces friction between chips, tools, and workpieces. Moreover, it has a great effect on the environment too. Minimum quantity lubrication can be used as an alternative of lubrication for clean machining. With an addition of nanoparticles into the minimum quantity lubrication, it is expected to enhance the machining performance that meets the environmental friendly purposes. Residual stresses remain in a solid material in the absence of external loading or thermal gradients, which is sometimes undesirable. The presence of compressive residual stresses is beneficial, while the presence of tensile stresses is detrimental. In order to study the residual stress and its relation with the surface quality (after milling process), the effects of reduced oil consumption in minimum quantity lubrication and the addition of SiO2 nanoparticles in minimum quantity lubrication for clean machining are presented in this research. Results indicate that there is an improvement in residual stresses and surface quality especially during conventional (up) milling under minimum quantity lubrication and minimum quantity lubrication–SiO2 nanolubrication condition.