In this current investigation, novel cutting fluids developed through a unique combination of food grade emulsifiers, plant based additives (EA) and nano particles (NP) as cutting fluid additives in corn oil (CO) based vegetable oil. Five dissimilar corn-based green cutting fluids (CBGC1, CBGC2, CBGC3, CBGC4, CBGC5) were prepared by varying the weight percentages (wt.%) of EAs (5, 10, 15, 20, 25) with CO, and their thermo-physical properties were meticulously analyzed. Among these formulations, CBGC2 demonstrated superior lubrication performance, making it the most promising oil for further investigation. Subsequently, the effect of different NP was investigated by adding alumina (Al2O3), graphene (Gr) and multi walled carbon nanotubes (MWCNT) NPs in the CBGC2 solution in the ratio of 0.4, 0.8 and 1.2 in weight percent (wt.%) and the experimental results reveal substantial enhancements in thermophysical properties. Among various samples, the nanofluid containing 0.8 wt.% concentration of Al2O3 nanoparticles in CBGC2 exhibited the highest viscosity. Additionally, the thermal conductivity of the nanofluid enhanced by 24.82% when 1.2 wt.% of Gr nanoparticles added oil compared to CBGC2. Furthermore, in tribological tests, CBGC2 with 0.4% Al2O3 exhibited the lowest frictional force among the prepared cutting fluids. The contact angle reduced to a maximum extent by 11.14% for cutting fluids containing 1.2% alumina nanoparticles. These findings suggest that these innovative green cutting fluid formulations with nano-additives hold great potential for improving machining processes in various industrial applications towards sustainability.
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