Performance Investigation of MQL Parameters Using Nano Cutting Fluids in Hard Milling

Tran Minh Duc,Tran The Long,Ngo Minh Tuan

doi:10.3390/fluids6070248

Abstract

Machining difficult-to-cut materials is one of the increasingly concerned issues in the metalworking industry. Low machinability and high cutting temperature generated from the contact zone are the main obstacles that need to be solved in order to improve economic and technical efficiency but still have to ensure environmental friendliness. The application of MQL method using nano cutting fluid is one of the suggested solutions to improve the cooling and lubricating performance of pure-MQL for machining difficult-to-cut materials. The main objective of this paper is to investigate the effects of nanofluid MQL (NFMQL) parameters including the fluid type, type of nanoparticles, air pressure and air flow rate on cutting forces and surface roughness in hard milling of 60Si2Mn hardened steel (50–52 HRC). Analysis of variance (ANOVA) was implemented to study the effects of investigated variables on hard machining performance. The most outstanding finding is that the main effects of the input variables and their interaction are deeply investigated to prove the better machinability and the superior cooling lubrication performance when machining under NFMQL condition. The experimental results indicate that the uses of smaller air pressure and higher air flow rate decrease the cutting forces and improve the surface quality. Al2O3 nanoparticles show the better results than MoS2 nanosheets. The applicability of soybean oil, a type of vegetable oil, is proven to be enlarged in hard milling by suspending nanoparticles, suitable for further studies in the field of sustainable manufacturing.

Highlights

In recent years, the effects of climate change span the physical environment, ecosystems and human societies and include the economic and social changes
The results show that the use of nanofluids improves the lubrication and cooling effects, thereby enhancing the machining performance
The results indicated that the better cutting performance and lower deformed chip thickness were reported in case of using nanofluids when compared to the case without nano additives

Summary

Introduction

The effects of climate change span the physical environment, ecosystems and human societies and include the economic and social changes. Humancaused climate change is one of the threats to sustainability. Environmentally friendly machining is a topic of increasing interest in the world. The reduction of cutting fluids is considered the most effective solution to minimize negative impacts on the environment and human health. Research has shown that up to 85% of cutting fluids in use are derived from mineral oil [1], so the discharge into the environment without going through recycling will destroy the environment. The very expensive treatment for the used oil puts the more pressure on the manufacturing expenses

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Conclusion