Abstract
With increasing environmental concerns, the substitution of mineral oil-based cutting fluid has become an urgent issue. Using vegetable soybean oil as base fluid, nanofluid cutting fluids (NFCFs) were prepared by adding different weight concentrations of nanographite particles (NGPs), and their penetration and lubrication performances were studied. A novel simulated tool-chip slit with micrometer-sized geometry was manufactured to evaluate and quantify the penetration rate of the NFCFs by image analysis approach. Moreover, a large number of comparative experiments on the closed-type broaching machine were carried out to compare the performance of the proposed NFCFs and a commercial cutting fluid in terms of cutting force, workpiece surface roughness, and metal chip. It is found that there is an optimal NGP concentration in NFCF for practical cutting applications. When the concentration of NGP is 0.4 wt%, the broaching process lubrication exhibits an ideal mixed lubricate state, resulting in minimal friction resistance, and thus, both the cutting force and chip curling angle reach their corresponding best values. Moreover, the proposed NGP-based vegetable-oil cutting fluid exhibits excellent environment-friendliness and low-cost consumption in the minimal quantity lubrication (MQL) method; this demonstrates its potential for replacing the traditional broaching cutting fluid.
Highlights
Cutting fluids are usually indispensable to modern cutting processes, wherein the fluid is responsible for lubrication, cooling, chip removal, and other functions [1,2,3]
Penetrativity of cutting fluids performs a major role in lubrication on the limited surface of the workpiece, tool, and chip since all cutting parameters were unchanged during the broaching process
The maximum penetration speed of 138 nL at 135 ms was recorded for NGP04
Summary
Cutting fluids are usually indispensable to modern cutting processes, wherein the fluid is responsible for lubrication, cooling, chip removal, and other functions [1,2,3]. In broaching or other cutting applications, the mineral oil-based cutting fluid is largely used because of its acceptable lubrication and cooling effect. Recent studies have shown that the mineral oil-based cutting fluid could cause great harm to the human body and environment [4,5,6,7], which would increase the probability of workers suffering from various diseases or the ecosystem being damaged by an improper discharge of waste cutting fluid. Belluco and de Chiffre [10] compared the machining effect of five vegetable oil-based cutting fluids and a commercial cutting fluid in drilling austenitic stainless steel. The experiments showed that the vegetable oil-based cutting fluids effectively reduced the cutting force and prolonged the tool life. Cetin et al [11] found that vegetable cutting fluid with a high concentration of extreme pressure agents can greatly reduce the cutting force when turning AISI 304 stainless steels. Lawal et al [12] studied the Friction 9(6): 1406–1419 (2021)
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