Effect Of Minimum Quantity Lubrication Research Articles

Experimental study on the effect of minimum quantity lubrication on the grinding surface/subsurface of nickel-based single-crystal superalloys

Experimental study on the effect of minimum quantity lubrication on the grinding surface/subsurface of nickel-based single-crystal superalloys

Synthesis and characterization of carbon-based MWCNT combined with CaO to improve the surface characteristics of DED-processed Ti64 alloy machined under MQL conditions

The capacity of additive manufacturing (AM) to create intricate geometries and minimise material waste has drawn a lot of attention. Nevertheless, post-processing steps like machining are frequently needed for AM components to improve their functional surfaces. High temperatures are produced at the tool-workpiece-chip contacts during cutting operations, which lowers tool life and efficiency. Although petroleum-based cutting fluids (CFs) are commonly used to control these temperatures, they pose environmental, health, and cost concerns. Minimum quantity lubrication (MQL) with vegetable oil (VO) has emerged as a promising alternative that offers improved machining performance and environmental friendliness. However, MQL’s effectiveness of MQL may be limited under aggressive machining conditions, necessitating the use of nanoparticles (NPs) to enhance performance. In this investigation, the wettability, dynamic viscosity, density, and thermal conductivity of multi walled carbon nanotubes (MWCNT) at varying wt. concentrations (0.25% to 1.25%) are examined. Following that, the milling tests are conducted in the following conditions: dry, flood, MQL (CaO), and nanofluid-MQL (N-MQL). The outcomes show that the addition of NPs to CaO reduces the contact angle to 15.53° at 1.00 wt%, indicating better wettability. Furthermore, the incorporation of MWCNTs results in a significant improvement in the dynamic viscosity, thermal conductivity, and density of the VO. N-MQL, on the other hand, results in an enhancement in surface quality in contrast to other cutting strategies.

Investigation of the effect of minimum quantity lubrication (MQL) on cutting forces and surface roughness in turning of AISI 1050 steel

Geleneksel soğutma yöntemlerinin gerek insan sağlığına gerekse çevreye vermiş olduğu zararlardan dolayı kullanımı son yıllarda oldukça azalmıştır. Bu soğutma yönteminin yerine daha çevreci, ekonomik ve geleneksel soğutma yöntemlerine göre insan sağlığı açısında olumsuzluk yaratmayacak olan soğutma yöntemi kullanılmaya başlanmıştır. Bu çalışmada AISI 1050 çeliği üç farklı kesme hızı (340, 400 ve 460 m/dak) ve iki farklı ilerleme miktarında (0,2 ve 0,3 mm/dev) tornalanmasında kesme şartlarının etkisi araştırılmıştır. Deneyler kuru kesme koşulunda ve 90, 150 ve 200 ml/saat minimum miktarda yağlama (MMY) akış hızında gerçekleştirilmiştir. Deneyler sonrasında kesme parametrelerinin ve kesme şartlarının ortalama yüzey pürüzlüğü ve kesme kuvvetleri üzerindeki etkileri incelenmiştir. Elde edilen değerler doğrultusunda minimum miktarda yağlama uygulamasının ve akış hızı artışının kesme kuvvetlerini ve ortalama yüzey pürüzlüğü değerlerini olumlu yönde etkilediği sonucuna ulaşılmıştır. En düşük ortalama yüzey pürüzlüğü değeri 1,42 µm olarak elde edilmiştir. En düşük kesme kuvveti ise 1084 N olarak ölçülmüştür.

Investigation of the effect of minimum quantity lubrication and Ranque–Hilsch vortex tube cooling on cutting forces, surface roughness and cutting zone temperature in turning Al 6082 T4 alloy

Aluminium alloys are widely utilized, particularly in the automotive and aerospace industries, because of their great corrosion resistance, high strength/density ratio and propensity to increase mechanical qualities during ageing. With this widespread use, there are also various machining problems. Therefore, in this study, the cutting forces, average surface roughness and cutting zone temperature of different cooling conditions in turning Al 6082 T4 alloy were investigated. In the experiments, three different cutting conditions (Ranque–Hilsch vortex tube (RHVT), minimum quantity lubrication (MQL), and dry) were used in the experiments. As cutting parameters, three cutting speeds and feed rates (500, 625 and 800 m/min and 0.1, 0.125 and 0.15 mm/rev) were chosen. Taguchi-based grey relation analysis was applied to the data obtained after the experiments. As a result, it has been observed that MQL and RHVT methods positively affect the cutting forces, average surface roughness and cutting zone temperature values. As a result of Taguchi-grey relational analysis, optimum results were obtained with RHVT cooling, 800 cutting speed and 0.1 feed rate.

Hard Turning of AISI D2 Steel Using CBN Tools under MQL: Assessment of MRR, Tool Life and Surface Integrity of the Workpiece

Hard turning (HT) is a machining method which is widely adopted nowadays to produce an improved surface finish without the application of a grinding process. The available literature conveys to us that studies have been done to improve surface finish by using small feeds and high speed. This study is an effort to enhance the tool life, material removal rate (MRR) and surface roughness of the workpiece by using different combinations of cutting factors and a lubricating technique called minimum quantity lubrication (MQL). The workpiece used for this experiment is AISI D2 steel and the used tool inserts are cubic boron nitride (CBN) tools. The HT of the workpiece is done under 3 different cutting velocities, feeds and depths of cuts. The flow rate for the MQL process is kept at 240 ml/hr. We observed that at the highest speed and lowest feed, the achieved surface roughness was the best. Furthermore, the MQL showed some great results in the context of tool life as it was improved by approximately 48% as compared to that of dry machining. Also, there was an improvement of up to 12% in the context of surface finish. However, there was not any effect of MQL on MRR as it purely relies on cutting velocity, depth of cut and feed. Also, it did not have any effect on theworkpiece and tool insert material used.

Study on helical milling of SS 304 with small diameter tools under the influence of minimum quantity lubrication (MQL)

The objective of the present work is to study the effect of minimum quantity lubrication (MQL) on the performance of helical milling for machining high-quality holes with a small-diameter tool. Helical milling with small tools (diameter < 5 mm) has been a challenging domain due to the problem of tool deflection, which deteriorates the hole quality and adversely affects the process efficiency. In this study, helical milling of stainless steel (SS 304) is carried to machine holes using a 3 mm diameter coated carbide tool in minimum quantity lubrication (MQL), and the performance is compared with dry and conventional flood cooling based on the hole quality and tool wear. The findings of this study reveal that MQL results in high-quality holes with the least circularity and cylindricity errors compared to dry and flood lubrication. Surface morphology study of the machined holes shows that the holes generated in MQL have smoother surfaces with no evidence of severe surface defects. MQL can also significantly mitigate the problem of tool deflection encountered in small-diameter tools and reduce tool wear by 33.3% and 21.7% compared to dry and flood lubrication, respectively. As per ISO 286-2 standard, hole quality up to grade H8 is achieved with MQL, while dry condition and flood lubrication yield hole quality corresponding to H9 grade. This study concludes that MQL-assisted helical milling is one of the sustainable alternatives for the production of high-quality small-diameter holes in stainless steel.

A Review on the Effect of Minimum Quantity Lubrication on Different Machining Parameters Emphasizing Vegetable Oil-Based Lubricants for Sustainable Manufacturing

The cutting fluid plays a significant role in minimizing heat generation and chip removal process during the machining of materials, hence improving tool life and surface finish of the workpiece. Many researchers have focused on minimum quantity lubrication (MQL) among the existing methods on the application of the coolant as it reduces the usage of coolant by spurting a mixture of compressed air and cutting fluid in an improved way instead of flood cooling. The MQL method has demonstrated to be appropriate as it fulfills the necessities of ‘green’ machining. Additionally, considering current environmental issues and provisions for safe healthy working conditions at the workplace, it is important to divert machining processes towards an eco-friendly path. Hence, the focus of research has been shifted to MQL using eco-friendly lubricants for green and sustainable manufacturing processes. In this review paper, the effect of different vegetable oil-based biodegradable coolants like castor oil, coconut oil, palm oil, etc. for different machining process parameters like cutting force, cutting temperature, surface finish, tool wear, etc. has been reviewed. It is observed that proper selection of cutting parameters along with lubricant through MQL can provide enhanced machinability to get desired outputs.

NEW GENERATION NANO-CBN CUTTING TOOL FOR INCREASING SUSTAINABILITY OF HARD TURNING PROCESS

In this paper, the effect of minimum quantity lubrication (MQL) on tool wear in the hard turning of 100Cr6 ball bearing steel has been investigated and the results are compared to those obtained through dry and wet lubrication methods. The tools used in the study include CBN and nano-CBN tools. The nano-CBN tool is a new generation of CBN tools manufactured based on nanotechnology. No research has been conducted on the impact of this tool on machining processes. The ratio of NCBN tool flank wear land to the CBN tool flank wear land in dry, wet and MQL methods were 0.18, 0.23 and 0.28, respectively. The wear of CBN tool in turning with MQL was 2.8 times greater than the wear of nano-CBN tool in dry machining. In turning with nano-CBN tool, the height of the tool flank wear with MQL was reduced by 22% and 7% concerning wet and dry methods, respectively, while these values were 51% and 24%, respectively, for the CBN tool. The CBN tool wear depends on the lubrication method but the wear of the nano-CBN tool is almost independent of the lubrication method.

Evaluating the effect of minimum quantity lubrication during hard turning of AISI D3 steel using vegetable oil enriched with nano-additives

Conventional flood lubrication techniques have serious impacts on the environment, health, and economy. Thus, the implementation of advanced lubrication techniques such as minimum quantity lubrication (MQL) has gained attraction worldwide as a reliable alternative to flood lubrication due to its effectiveness and eco-friendly characteristics. In order to increase the efficiency of MQL, nanoparticles have recently been added to the base fluids to improve the performance of lubrication thanks to their thermo-physical properties. In this work, an eco-friendly vegetable oil called rice bran oil (RBO) was used as a lubrication fluid with and without the addition of zinc oxide (ZnO) nanoparticles in order to investigate their influence on the turning performance characteristics, in terms of cutting force, surface roughness, flank wear and cutting temperature, during hard turning of AISI D3 steel. Taguchi L16 orthogonal array was implemented to investigate the effect of turning parameters including cutting speed, feed rate, and depth of cut on the response variables. The results showed that ZnO nanoparticles-enriched base fluid gives better performance than machining with a pure oil in terms of mitigating the severity of cutting force by about 10.68–18.48%, reducing tool wear by about 9.33–51.96%, and reducing the roughness of the machined surface by 3.86–12.84%.

Analysis of vegetable oil-based nano-lubricant technique for improving machinability of Inconel 690

Conventional cutting fluids are applied to dissipate the heat generated in the cutting zone during machining. However, the use of metal cutting fluids causes adverse impacts on workers' health and the environment. Minimum quantity lubrication (MQL) has drawn attention to eliminating the use of mineral-based cutting fluids. The effectiveness of MQL can be further enhanced by employing vegetable oil and nanoparticles. Nanofluid-based lubricants result in superior heat transfer capacity and improved lubricity. In this context, the performance of vegetable oil mixed with and without molybdenum disulfide nanoparticles (nMoS2) applied with MQL is investigated during the machining of Inconel 690. The nanoparticles with different concentrations (0.5%, 1%, and 1.5%) are added in canola oil, and friction coefficient, thermal conductivity, viscosity, and wettability of nanofluids are analyzed. The machining experiments are performed under dry, flood cooling, MQL, and nMQL. The machining performance is evaluated by measuring tool wear, surface roughness, chip morphology, cutting temperature, and energy consumption. The findings revealed the superiority of nMQL with 54%, 29%, and 13% reduction in surface roughness and 56%, 39%, and 12% reduction in energy consumption compared to dry, flood cooling, and MQL environments. Also, nMQL has led to longer tool life. The effectiveness of nMQL has resulted in better tribological conditions in the cutting zone with enhanced cooling/lubricating action of vegetable oil and lamellar structure of nMoS2. The results show a significant role of nano-cutting fluid-based lubricant applications in the machining industry to meet energy-saving and sustainability goals without compromising product quality.

Effects of minimum quantity lubrication (MQL) in grinding: Principle, applications and recent advancements

Increasing the production rate and simultaneously decreasing the cost of production is the target of every industrial house in the world. While coming to the production house the prime concern is to increase the cutting tool life of different machines. Numerous methods are available to achieve the desired target. Decreasing the temperature by removing heat from the machining zone is one of the methods of increasing the tool life. To remove the heat, different ways of cooling and lubrication are available like, dry machining, flooded type cooling, cold air cooling, minimum quantity lubrication (MQL), cryogenic cooling, tool texturing, solid lubrications, tool designing to name a few. Although the traditional flooded type cooling system gives good result but environmental point of view it is not a sustainable way hence the concern is how to reduce the cost of lubrication without sacrificing the quality. In the past few years more research is concentrated on MQL and mainly on hybrid mode of cooling methods like MQL with air cooling, MQL with cryogenic, MQL with different environment friendly oils etc. This article discusses different methods of sustainable cooling, advantages, limitations, applications of MQL, and the last section focuses on recent advancements in MQL in the field of grinding operation. This article will help to develop good knowledge about MQL and the recent advancements and shortcomings in the field of grinding in context with cooling and lubrication with MQL.

Effect of Minimum Quantity Lubrication on Surface Roughness in Keystone Grinding

Effect of Minimum Quantity Lubrication on Surface Roughness in Keystone Grinding

A comprehensive study on minimum quantity lubrication

The cutting fluid plays a significant role by cooling the surface of tool, substrate and removing chips from the cutting area during metal machining operations (turning, milling, grinding etc.). However, by adopting the conventional method of cooling (flood cooling), it affects the human health and the environment badly. In addition, it accounts for 16–20% of the total cost of manufacturing in the production industry. To overcome this issue, minimum quantity lubrication (MQL) is gaining higher potential for attaining good quality surface and improved overall performance of machining than conventional cooling methods. Because MQL system reduce the use of coolant by depositing the suitable mixture of cutting fluid and compressed air during machining in optimum quantity. In general the amount of cutting fluid in MQL system is in ml/hr instead of in l/min as in flood cooling. Beside these benefits of MQL system, it also decreases the cutting forces, tool wear, temperature and friction during machining. Hence the aim of this paper is to provide an overview of MQL system, cutting fluids and effect of MQL on the machining performance during turning operation. The study revealed that by employing MQL system in turning results in significant enhancement in metal removal rate and surface finish by 30% and reduced cutting force (by 17.07–40%), cutting temperature (by 6.72–10%), tool wear and eliminated built up edge. Overall this improved the overall performance of the machining.

Investigation of the Effects of Nanoparticle Concentration and Cutting Parameters on Surface Roughness in MQL Hard Turning Using MoS2 Nanofluid

Minimum quantity lubrication (MQL) has gained significant attention in various research fields and industrial applications for its advantages of being environmentally friendly and suitable for sustainable production. The effectiveness of MQL is increasing significantly by using nano cutting fluid, which can be produced by suspending nanoparticles in the based cutting fluid. This study aims to investigate the effects of MoS2 nanoparticle concentration, cutting speed, and feed rate on MQL hard turning of 90CrSi steel in terms of surface roughness and surface microstructure. The Box–Behnken experimental design was used to analyze the influence of input parameters and their interaction effects as well as to find the optimal set of variables. The obtained results prove the improvement of the machinability of carbide tools due to higher cooling and lubricating performance created by MoS2 nanofluid MQL, which contributes to improve the surface quality and reduce the manufacturing cost. There is an interaction effect between nanoparticle concentration and feed rate which has a strong influence on surface roughness.

Influence of graphene reinforced sunflower oil on thermo-physical, tribological and machining characteristics of inconel 718

Owing to the extreme heat generated during Inconel 718 machining, the application of a minimum quantity lubrication (MQL) strategy is restricted to mild cutting conditions. By incorporating vegetable-based cutting oils reinforced by nanoparticles as possible additives, the effectiveness of MQL can be improved in high-speed machining. In this study, hybrid nano-green oils were developed by combining graphene nanoparticles in various volume concentrations with sunflower oil. Subsequently, dispersion stability, thermal conductivity, viscosity, and wetting angle of nano-green oils were measured. An MQL device is used to disperse the smallest amount of nano-green oils throughout the machining area. Later, the experimentally optimized graphene-based green oil is used for milling experiments. Furthermore, hard machining experiments were conducted with cutting speed of 80 m/min, feed rate of 0.2 mm/rev, and depth of cut of 0.5 mm under four different lubricating mediums: dry, flooded, sunflower oil, and 0.7% graphene reinforced sunflower oil. Comparative results show that 0.7% graphene reinforced sunflower oil performs better and reduces surface roughness by 49%, cutting force by 25%, cutting temperature by 31%, and tool wear by 20% as compared to dry machining environment. Finally, elemental analysis of cutting insert reports that adhesion is the major wear mechanism in all mediums.

The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel

Minimum quantity lubrication (MQL) is a sustainable method that has been efficiently applied to achieve machinability improvements with various materials in recent years, such as hardened steels, superalloys, soft metals, and composites. This study is the first to focus on the performance evaluation of MQL and dry milling environments with AISI 1040 steel. The tool wear, cutting temperature, and power consumption were considered as the quality responses while cutting speed, feed rate and machining environment are taken as input parameters. The effects of the influential factors are analyzed using analysis of variance (ANOVA) and bar charts. Additionally, Taguchi signal-to-noise (S/N) ratios are utilized in order to determine the optimum parameters for the best quality responses. The results show that the MQL system provides better performance compared to dry milling by reducing the tool wear, cutting temperature, and power consumption. According to the ANOVA results, the cutting environment affects the cutting temperature (37%) and power consumption (94%), while cutting speed has importance effects on the tool wear (74%). A lower cutting speed (100 m/min) and feed rate (0.10 mm/rev) should be selected under MQL conditions to ensure minimum tool wear and power consumption; however, a higher feed rate (0.15 mm/rev) needs to be selected along with a low cutting speed and MQL conditions to ensure better temperatures. A comparative evaluation is carried out on the tool wear, cutting temperature, and power consumption under MQL and dry environments. This investigation is expected to contribute to the current literature, highlighting the superiority of sustainable methods in the milling of industrially important materials.

Experimental investigation on the performance of composite electrostatic spraying milling using different inner/outer fluid combinations

Electrostatic spraying (ES) can improve the machining and environmental effects of minimum quantity lubrication (MQL). Compared with ES, composite electrostatic spraying (CES) presents better results because of excellent charging and cooling/lubrication performances. This article investigated the performance of CES milling using different inner/outer fluid combinations in terms of milling force, tool wear and oil mist concentration. Four inner/outer fluid combinations were employed in the study, namely, water/LB2000, multiwalled carbon nanotubes (MWCNTs)-water nanofluid/LB2000, water/MWCNTs-LB2000 nanofluid and MWCNTs-water nanofluid/MWCNTs-LB2000 nanofluid. For the analysis of the performance of CES milling, the charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. The results show that MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling from the view point of machining and environmental performances because of superior charging property, atomization stability and friction-reducing effect of nanoparticles. Highlights The performance of CES milling using different inner/outer fluid combinations was studied in terms of milling force, tool wear and oil mist concentration. The charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling.

Improvement in machining process performance using solid lubricant assisted minimum quantity lubrication

ABSTRACT To improve the quality of the product produced considering productivity, it is important to evaluate the factors affecting the machining experimentally and analytically. Looking at the harmful effects of conventional cutting fluid on the environment and workers’ health, in the current research work effort has been made to explore the effectiveness of minimum quantity lubrication (MQL) and solid lubricant in machining. Micron-sized calcium fluoride (CaF2) solid lubricant powder particles are mixed in SAE 40 cutting oil and applied to the machining area with minimum quantity lubrication. The effect of different particle sizes and wt% of CaF2 has been analysed by measuring surface roughness, chip-tool interface temperature, flank wear of the tool, and cutting forces. Results demonstrated that the smaller size and 20 wt% of CaF2 powder have improved the process performance by lowering surface roughness and tool wear. The effectiveness of solid lubricant can be viewed as an alternative compared to wet machining. The results can be used by related industries to improve machining performance with the use of MQL and solid lubricants leading towards clean and sustainable manufacturing.

An experimental investigation of effect of minimum quantity lubrication in machining 6082 aluminum alloy

An experimental investigation of effect of minimum quantity lubrication in machining 6082 aluminum alloy

Multi response optimization of process variables in MQL assisted face milling of EN31 alloy steel using grey relational analysis

Temperature has immense effect on the surface conditions of the specimen in machining process. The traditional method for lowering the temperature used in industries is flood cooling which leads to lots of environmental and health concerns. In the present work, the effect of minimum quantity lubrication has been analyzed for the outputs like cutting temperature and surface roughness in machining of EN31 alloy steel. The technique used for this multi-response optimization is Taguchi based grey relational analysis. This technique is used to conclude the best possible levels of process variables (cutting depth, feed, cutting speed and lubricant flow rate). After validation of results, the optimal conditions for process parameters achieved are speed at 700 rpm, feed at 140 mm/min, depth of cut as 0.3 mm and lubricant flow rate as 150 ml/hr. Lubricant flow rate proves its significance for the aforementioned parameters.