Reinforced lubrication of vegetable oils with nano-particle additives in broaching

Abstract

Application of cutting fluids in broaching process plays a significant role in minimizing production cost and energy. However, conventional broaching fluids contain harmful and destructive chemical constituents, causing various environmental threats and operator hazards. Vegetable oil-based nano-cutting fluids are good alternatives owing to their less environmental threats, high thermal conductivity and supreme lubricating efficiency. The current study concentrates on the application of green vegetable oil-based cutting fluids in the broaching process. Firstly, conventional broaching oil (CBO) and five vegetable oils are proposed as cutting fluids. The sesame oil is preferred by analyzing the coefficient of friction (COF) and molecular structure of vegetable oils. Afterward, CuO, Al 2 O 3 , Fe 3 O 4 and carbon powder nanoparticles were added into the sesame oil to prepare nanofluids. The CuO nanoparticle was selected to perform the further optimization because of its special particle shape and physical properties. Finally, the best concentration of CuO nanofluid, 0.54 wt%, was obtained by observing the distribution of nano-particles in the nanofluids. The results show that 0.54 wt% CuO nanofluid reduces the peak and trough loads amounted to 887 N and 774 N, respectively which are 62.7% and 68.6% higher than those of the pure sesame oil. • Sesame oil could effectively reduce the broaching load. • CuO nano-particle has the best load reduction capability. • CuO nano-particle significantly reduces cutting energy consumption. • Within a certain limit, broaching nano-fluid lubrication effect increases with increasing concentration. • Optimum concentration of nano-particles stays at 160 mg with host fluid sesame oil.