Lubrication Machining Research Articles

Multi-objective parametric modelling during minimum quantity lubrication machining of Incoloy 800H

Multi-objective parametric modelling during minimum quantity lubrication machining of Incoloy 800H

Analysis of the Sustainable Cooperation between a Multi-Piped Impeller and a Concentric Casing Using Experimental Planning

Centrifugal pumps are one of the most commonly used devices in all branches of industry. Their application area is very broad and practically related to all sectors of the economy. Such pumps are widely applied in the chemicals industry, liquid gas technology, and machine lubrication systems, among others. On the basis of available data, it can be assumed that pumps consume approximately 27% of the world’s electricity. For this reason, their efficiency has a significant impact on the energy consumption of many technological processes. This article presents a summary of the research concerning the cooperation between a multi-piped impeller and a concentric casing. A multi-piped impeller is a completely new concept of a centrifugal impeller, which is characterized by the fact that the energy of the liquid is transferred as a result of the flow of media through the internal flow channels, and also the flow of media around it. The type and design of the casing, with regard to the flow in it and around the impeller’s pipes, plays an extremely important role. Numerical analysis was used as the main research method, which was based on a rotatable experimental plan. The CFD simulation results were validated on a test stand. Finally, the mathematical model and the rules for selecting the geometric features of such a stator were proposed in order to achieve the highest possible efficiency when cooperating with the multi-piped impeller, which constitutes a scientific novelty.

Combination of minimum quantity lubrication (MQL) with solid lubricant (SL): challenges, predictions and implications for sustainability

This literature review explores minimum quantity lubrication (MQL) machining, emphasizing its benefits over traditional dry and flooded cooling methods. MQL is vital in manufacturing, enhancing productivity and sustainability. Adding solid lubricants (SL) amplifies MQL’s advantages. This article identifies challenges in MQL + SL machining and outlines future research opportunities. A comprehensive four-step review was conducted: identifying research gaps, determining databases and search terms, defining paper selection methods and performing bibliometric analysis. The review abstracted information from selected articles, offering in-depth discussions. Challenges in MQL machining involve forces, temperature, tool wear, roughness and lubricant performance. Studies show incorporating SL into base fluids mitigates these issues. Sustainability is a core focus in modern manufacturing, and MQL’s eco-friendly reputation is deserved. MQL with SL, often in nanoparticle form, provides benefits like reduced friction, enhanced tool life, lower energy consumption and improved material disposal. In conclusion, MQL + SL machining offers a promising path to balance productivity and sustainability. Continued research and development are essential to overcome challenges and unlock its full potential. As manufacturing evolves, MQL + SL machining exemplifies innovation and sustainability, poised to reshape the industry’s future.

Improving the performance of cutting fluids by using ZnO and ZrO2 nanoparticles

Sustainability is nowadays a global research priority, especially in machining, where optimizing production processes for increased productivity, profits, and efficiency is key. Addressing this need, the adoption of nanofluids in minimum quantity lubrication machining has surged, aligning with environmental concerns and regulatory demands. In this study, sustainable zinc oxide (ZnO) and zirconium dioxide (ZrO2) nanoparticles fabricated using plant extracts have been incorporated into conventional cutting fluids to enhance their machinability performance under minimum quantity lubrication for turning process. The microstructural analysis confirms the successful synthesis of the targeted nanoparticles with excellent purity and size distribution. The addition of nanoparticles significantly enhanced thermal conductivity from 0.5916 W/(m⋅K) for the base fluid to 0.6286 W/(m⋅K) for ZnO and to 0.6242 W/(m⋅K) for ZrO2. Further, nanofluids exhibited an increased dynamic viscosity, 1.435 mPa.s for ZrO2 and 1.125 mPa.s for ZnO as compare to 0.7644 mPa.s of base fluid, attributed to the nanoparticle confinement effect whereas contact angle measurements indicated an improved wettability for all nanofluids. Machining experiments validate the efficacy of nanofluids, demonstrating reduced cutting temperatures and enhanced surface finish. Notably, ZrO2-based nanofluids exhibit improved tribological response, while ZnO-based nanofluids showcase exceptional heat transfer ability, offering promising solutions to key technical challenges in machining processes. In conclusion, this study underscores the potential of green, sustainable ZnO and ZrO2 nanoparticles as additives in cutting fluids, poised to revolutionize metalworking and manufacturing processes, thereby enhancing product quality and sustainability.

Surface topography and corrosion resistance of AISI 630 stainless steel after finish turning under different cooling methods

AISI 630 stainless steel (SS) is widely used for medical devices. This paper describes the effects of dry, flood and minimum quantity lubrication (MQL) machining conditions on the surface topography and corrosion resistance (CR) of AISI 630 SS after finish turning. Small areas of valleys and large areas of peaks were observed on the surfaces with minimum surface roughness (SRmin) after dry machining at the feed rate (f) of 0.1 mm/rev and at the f = 0.14 mm/rev using the MQL method. Only small areas of peaks were observed after flood machining at the f = 0.1 mm/rev. Regardless of cooling methods, regularly distributed deep valleys and high peaks were observed on the surfaces with maximum surface roughness (SRmax) machined at the f = 0.35 mm/rev. Surfaces of the samples with SRmin and SRmax under flood machining and with SRmax under MQL machining had high oxygen content in the range of ∼ (20−30) %wt. during 7–72 days of the sample storage in SBF. Such an oxygen content is observed on the machined surfaces for which maximum peak height Sp parameters were in the range of ∼ (10–16) μm and maximum valley height Sv – ∼ (8–10) μm. Compared to SRmin, high ion diffusion was observed on surfaces with SRmax. This means that surfaces with regular deep valleys and high peaks provide high ion mobility between them. In addition, compared to dry and MQL machining, higher resistivity was obtained for the samples under flood machining. Depending on the industrial application requirements, the passivity and CR of AISI 630 SS can be modulated by selecting machining conditions and surface topography. It has been established that in order to achieve favorable CR of the AISI 630 SS surface after finish turning, the flood method is recommended.

Nano lubricants in machining and tribology applications: A state of the art review on challenges and future trend

Nanofluids are a unique class of fluids generally prepared by adding nanosized particles to different types of base fluids, such as water, oil, etc. When nanoparticles are added to the base fluids, their thermophysical parameters like viscosity, heat transfer characteristics, and thermal conductivity are improved and provide good results. For this reason, the demand for fluids enriched with nanoparticles has considerably increased in the manufacturing sector. This comprehensive state-of-the-art review covers nanolubricants' role in friction reduction, wear resistance, and machining efficiency applications. Initially, the lubricants and their properties are revealed in the introduction section. Then, the different types of nanoparticles, their basic structure, and their different applications in machining and tribology are portrayed in different sections. In addition, it provides a comprehensive analysis of the difficulties related to nanofluids and their utilization in machining and tribology. Ultimately, this evaluation provides final comments on the latest advancements in both the academic and industrial sectors, as well as a strategy for future expansion. The results indicated that the fluids loaded with nanoparticles had a beneficial effect in lowering friction and temperature at the primary contact zone.

A comprehensive review of minimum quantity lubrication (MQL) machining technology and cutting performance

A comprehensive review of minimum quantity lubrication (MQL) machining technology and cutting performance

Elevating Sustainability: The Role of Machining in Modern Eco-Friendly Manufacturing Processes

Sustainable manufacturing has become a critical concern across various industries, including aerospace, automotive, and services. It involves the creation of manufactured products through economically sound processes that minimize negative environmental impacts while conserving energy and natural resources. Additionally, sustainable manufacturing aims to enhance employee, community, and product safety.This paper focuses on the machining process as a key component of sustainable manufacturing. Machining is widely used in manufacturing industries to fabricate components, but it also significantly contributes to environmental pollution. Sustainable machining has been a topic of discussion for over a decade. In sustainable machining processes, every factor acts differently like, the tool life, productivity, and effective utilization of resources must be increased. In contrast, the machining cost, machine cutting power, and adverse effect of cooling and lubrication fluids will be decreased. Important aspects of sustainable machining include dry and near-dry machining, cryogenic machining, and minimum quantity lubricant (MQL) were presented in this article. The effectiveness of these processes is assessed based on cutting tool life and the quality of machined components. In addition, the advancements consideration such as novel process variations, process hybridization, the use of sustainable tools and green transfer mediums, and the optimization of process parameters. Recommendations include increasing efficiency and reducing waste by incorporating recyclable tools in the machine industry implementing either stand alone or hybrid sustainable lubrication machining techniques.

Investigation on lubricity effectiveness Ficus carica lubricant modified with PTFE and TBHQ as additives for steel-steel contact application

The application of additives to the bio-lubricants is essential to improve the base oil tribological properties. A high-frequency reciprocating rig and different operating conditions were used to test the effects of tert-butylhydroquinone (TBHQ) and polytetrafluoroethylene (PTFE) polymer on the tribological performance of Ficus carica oil as a base oil for machine lubrication. The viscosity and Fourier transform infrared spectroscopy (FT-IR) evaluations were carried out to ascertain the additive's effectiveness. A scanning electron microscope was used to analyse the morphologies and the substrate-worn surfaces. When additives were applied separately, 1 wt% of PTFE produced a superior coefficient of friction (COF) and better wear reduction than other examined samples. In terms of wear resistance, commercial lubricant oil (CLO) SAE 5 W-30 performed better than the optimal 1 wt% PTFE + 0.3 wt% TBHQ blended with Ficus carica oil (FCO/L). At an increased frequency of 5 Hz, CLO outperformed FCO/L on COF and wear resistance. When examining the worn surfaces, less iron (Fe) was discovered on the FCO/L than the base Ficus carica oil, demonstrating the mending effect of the used additive as the underlying mechanism of wear reaction. The results show promising potential for the new formulation of a green lubricant since the tribological characteristics of Ficus carica oil were improved by the addition of the selected additives.

Tool wear analysis in AISI 52100 steel machining with sustainable approach

ABSTRACT Manufacturing industries work towards the development of low toxic, eco-friendly, and sustainable alternatives to save the ecosystem from the harmful effects of traditional cutting fluids used for machining from long decades. The utilization of solid lubricants in machining is an advance alternative aimed at regulating the temperature in the machining zone without causing environmental pollution. The present study illustrates the machining performance of AISI 52100 steel employing solid lubricant-assisted machining (SLAM). The study evaluates the machining performance of SLAM with respect to cutting forces, vibration acceleration, tool wear, chip morphology, and surface roughness against dry machining (DM). The experimental findings indicate that utilizing SLAM leads to a notable decrease in cutting forces, ranging between 45% to 60%, a reduction in vibration acceleration by 14% to 29%, a decrease in tool wear by 11% to 17%, and a substantial improvement in surface finish ranging from 47% to 66% compared to DM.

A review on minimum quantity lubrication in machining of different alloys and superalloys using nanofluids

A review on minimum quantity lubrication in machining of different alloys and superalloys using nanofluids

Dry and Minimum Quantity Lubrication Machining of Additively Manufactured IN718 Produced via Laser Metal Deposition

Inconel 718 (IN718), a Ni-based superalloy, is immensely popular in the aerospace, nuclear, and chemical industries. In these industrial fields, IN718 parts fabricated using conventional and additive manufacturing routes require subsequent machining to meet the dimensional accuracy and surface quality requirements of practical applications. The machining of IN718 has been a prominent research topic for conventionally cast, wrought, and forged parts. However, very little attention has been given to the machinability of IN718 additively manufactured using laser metal deposition (LMD). This lack of research can lead to numerous issues derived from the assumption that the machining behavior corresponds to conventionally fabricated parts. To address this, our study comprehensively assesses the machinability of LMDed IN718 in dry and minimum quantity lubrication (MQL) cutting environments. Our main goal is to understand how LMD process variables and the cutting environment affect cutting forces, tool wear, surface quality, and energy consumption when working with LMDed IN718 walls. To achieve this, we deposited IN718 on SS309L substrates while varying the following LMD process parameters: laser power, powder feed rate, and scanning speed. The results unveil that machining the deposited wall closer to the substrate is significantly more difficult than away from the substrate, owing to the variance in hardness along the build direction. MQL greatly improves machining across all processing parameters regardless of the machining location along the build direction. Laser power is identified as the most influential parameter, along with the recommendation for a specific combination of power feed rate and scanning speed, providing practical guidelines for optimizing the machining process. While MQL positively impacts machinability, hourly energy consumption remains comparable to dry cutting. This work offers practical guidance for improving the machinability of LMDed IN718 walls and the successful adoption of LMD and the additive–subtractive machining chain. The outcomes of this work provide a significant and critical understanding of location-dependent machinability that can help develop targeted approaches to overcome machining difficulties associated with specific areas of the LMDed structure. The finding that MQL significantly improves machining across all processing parameters, particularly in the challenging bottom region, offers practical guidance for selecting optimal cutting conditions. The potential economic benefits of MQL in terms of tool longevity without a substantial increase in energy costs is also highlighted, which has implications for incorporating MQL in several advanced manufacturing processes.

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

AbstractNanoparticle-enhanced coolants (NPECs) are increasingly used in minimum quantity lubrication (MQL) machining as a green lubricant to replace conventional cutting fluids to meet the urgent need for carbon emissions and achieve sustainable manufacturing. However, the thermophysical properties of NPEC during processing remain unclear, making it difficult to provide precise guidance and selection principles for industrial applications. Therefore, this paper reviews the action mechanism, processing properties, and future development directions of NPEC. First, the laws of influence of nano-enhanced phases and base fluids on the processing performance are revealed, and the dispersion stabilization mechanism of NPEC in the preparation process is elaborated. Then, the unique molecular structure and physical properties of NPECs are combined to elucidate their unique mechanisms of heat transfer, penetration, and antifriction effects. Furthermore, the effect of NPECs is investigated on the basis of their excellent lubricating and cooling properties by comprehensively and quantitatively evaluating the material removal characteristics during machining in turning, milling, and grinding applications. Results showed that turning of Ti–6Al–4V with multi-walled carbon nanotube NPECs with a volume fraction of 0.2% resulted in a 34% reduction in tool wear, an average decrease in cutting force of 28%, and a 7% decrease in surface roughness Ra, compared with the conventional flood process. Finally, research gaps and future directions for further applications of NPECs in the industry are presented.

Experimental and numerical investigation of cooling effectiveness of nano minimum quantity lubrication

The literature on nano-minimum quantity lubrication (NMQL) machining suggests that its effectiveness is due to the increased thermal conductivity of the base oil and the reduced friction at the cutting interface due to the rolling effect of the nanoparticles. However, the relative contribution of the increased nanofluid thermal conductivity and nanofluid lubricity on the performance of NMQL has not been investigated. This study presents an experimental and a numerical investigation of NMQL cooling effectiveness and compares it with that of pure minimum quantity lubrication (MQL). A lumped system analysis was carried out on a flat Inconel workpiece with different heat inputs. Two different heat sources, an aluminum electric resistor and a propane torch, were used for three different cooling strategies: dry, MQL and NMQL. A propane torch was used to replicate the machining operational conditions involving vaporization of the base oil. The experimental results showed minimal improvements in the cooling effectiveness and the heat transfer coefficient of NMQL cooling when compared to MQL. There was less than a 1 % reduction in the surface temperature of the workpiece when using NMQL cooling compared to that of MQL. Additionally, the increase in the heat transfer coefficient for a flow rate of 22 ml/h was 1.07 %, while an increase of 1 % was observed at a flow rate of 44 ml/h. The experimental results suggest that the benefits of nano minimum quantity lubrication observed in the literature could be mostly associated with the lubrication benefits of the nanoparticles. This conclusion was derived from the experimental comparisons of the cooling effectiveness of NMQL over MQL, which yielded only minor improvements. Additionally, this paper presents a novel multiphase numerical model for NMQL. This model considered nanoparticles as distinct discrete particles along with the oil droplets, and it captured the flow conditions, average surface temperatures, and average heat transfer coefficient. This CFD model estimated the surface temperatures with errors below 10 %, while the heat transfer coefficient values had an average error of 12.05 %. This is the first attempt in the open literature to model a nano minimum quantity lubrication and cooling strategy using a two-phase approach.

Palm oil as an alternative bio lubricant: A review

Lubrication in mechanical operations involving relative motions of machine elements have been known to facilitate longer techno-economic life span of machine and its components. Lubrication reduces wear and tear of contacting surfaces in relative motion by creating a lubricous layered gap of fluid, powder or semi-solid like grease. Lubricant has also been proven to move heat away from rubbing surfaces to enhance thermal stability of their operations. Various methods, substances and technologies have been adopted to achieve the desired smooth running, minimize frictional losses and improve the thermal stability in the machine members. Mineral oils of long chain hydrocarbon as base oil have really gained ground as an extremely popular choice either in liquid or semi-solid state as lubricant. Recent research has however revealed that mineral oils are non-biodegradable, prone to pollution and hence constitute enormous risks to the environment. This observation and the need for a friendly environment have aroused the curiosity of researchers in the field of tribology and material engineering to the onerous challenge of finding alternative lubricants that will be harmless to the ecosystem and easy disposal of after use. Chief amongst the suggestions made towards the discovery of an environmentally friendly lubricant is the use of vegetable oils of distinct species. The identification of the potential available in vegetable oils has been demonstrated in certain classical operations requiring moderate temperature such as machining and few other cold working operations. This review examines the previous studies regarding the discovery of an alternative machine lubricant from the available vegetative seed oils, particularly palm oil, and suggests ways to improve previous findings and potentials.

Nanofluids Minimal Quantity Lubrication Machining: From Mechanisms to Application

Minimizing the negative effects of the manufacturing process on the environment, employees, and costs while maintaining machining accuracy has long been a pursuit of the manufacturing industry. Currently, the nanofluid minimum quantity lubrication (NMQL) used in cutting and grinding has been studied as a useful technique for enhancing machinability and empowering sustainability. Previous reviews have concluded the beneficial effects of NMQL on the machining process and the factors affecting them, including nanofluid volume fraction and nanoparticle species. Nevertheless, the summary of the machining mechanism and performance evaluation of NMQL in processing different materials is deficient, which limits preparation of process specifications and popularity in factories. To fill this gap, this paper concentrates on the comprehensive assessment of processability based on tribological, thermal, and machined surface quality aspects for nanofluids. The present work attempts to reveal the mechanism of nanofluids in processing different materials from the viewpoint of nanofluids’ physicochemical properties and atomization performance. Firstly, the present study contrasts the distinctions in structure and functional mechanisms between different types of base fluids and nanoparticle molecules, providing a comprehensive and quantitative comparative assessment for the preparation of nanofluids. Secondly, this paper reviews the factors and theoretical models that affect the stability and various thermophysical properties of nanofluids, revealing that nanoparticles endow nanofluids with unique lubrication and heat transfer mechanisms. Finally, the mapping relationship between the parameters of nanofluids and material cutting performance has been analyzed, providing theoretical guidance and technical support for the industrial application and scientific research of nanofluids.

A Study on the Effects of Hybridized Metal Oxide and Carbonaceous Nano-Cutting Fluids in the End Milling of AA6082 Aluminum Alloy

Finding an alternate solution for supplanting the existing conventional lubricant in machining is a challenge. This work narrows the search down to the use of nano-cutting fluids, as they exhibit excellent properties such as high thermal conductivity and good lubricity. A technical analysis of the performance of hybrid nano-cutting fluids in the end milling of AA6082 aluminium alloy in a constrained end milling condition is presented. Alumina and carbon nanotubes were chosen in this study for their better physical characteristics and compatibility during machining. Coconut oil was chosen as the base fluid (dispersal medium) as it provides good lubricity and better dispersion of nanoparticles due to its excellent rheological behaviour. The hybrid nanofluid was prepared by mixing alumina-based nanofluid with carbon nanotube nanoparticles in different volumetric concentrations. The thermo-physical properties of the prepared hybrid nanofluid were tested. Furthermore, they were tested for their spread-ability and other mechanical properties. Later, their performances as cutting fluid were studied with the minimum quantity lubrication (MQL) technique, wherein nanoparticle mist was formed and evaluated in the end milling of AA6082 aluminium to reduce the quantity of nanofluids’ usage during end milling. The controllable parameters of speed, feed rate, and type of cutting fluid were chosen, with the levels of cutting speeds and feed rate at 75–125 m/min, and 0.005–0.015 mm/tooth, respectively, and the response parameters studied were surface roughness and tool wear. The results show that better performance is achieved in hybridized nano-cutting fluid, with a sharp improvement of 20%, and 25% in tool wear and surface roughness when compared to the base fluid. This study has explored the concept of hybridization and the capability of nanofluids as cutting fluids that can be used as eco-friendly cutting fluids in manufacturing industries.

Multiscale simulation approach to predict the penetration depth of oil between chip and tool during orthogonal cutting of AISI 4140

Cooling lubricants in machining perform important tasks, from cooling and lubrication of the friction partners in contact to the removal of the separated chips. An essential, determining and largely unresolved question in relation to cooling lubricants in machining is to what extent the coolant can get into the cutting zone. The aim of this paper is to address this question by using a multiscale approach to determine the penetration of the cooling lubricant gap. This is achieved by multiscale simulations by means of coupling the results of flow, structural and continuum mechanical simulations. Comparatively, the results of the simulated machining operation are compared with experimental orthogonal cutting tests of AISI 4140.

Characteristics of Hybrid Nanolubricants for MQL Cooling Lubrication Machining Application

Efficient and effective lubricants have great application prospects in the manufacturing industries. Minimum quantity lubrication (MQL) machining with low flow rate of nanolubricants is investigated for cooling and lubrication during the process. This paper investigates the characterization of graphene-mixed aluminium oxide (G-Al2O3) hybrid nanomixture spent lubricants for MQL machining purposes. The main advantage of this method is to reduce the disposal lubricants to develop high-performance cooling-lubrication by using nanolubricants of G-Al2O3 nanoparticles in different volume composition ratios at a constant 1.0% volume concentration in a base liquid mixture of 40% spent lubricants. Before conducting the measurements of the nanolubricants’ thermal conductivity and dynamic viscosity, the nanolubricants were homogenous and stable. The tribological performance of all ratios was evaluated by using a four-ball wear tribotester machine. The thermal conductivity peak value for the G-Al2O3 hybrid nanolubricant was obtained and the highest enhancement, up to 29% higher than the base liquid solution, was obtained. The dynamic viscosity variation for all ratios was lower than the 40:60 ratio. The properties enhancement ratio suggests that G-Al2O3 hybrid nanolubricants with 1.0% volume concentration aid in the heat transfer, especially for ratios of 60:40 and 20:80. The lowest coefficient of friction (COF) for a ratio of 60:40 was obtained to be 0.064, with 45% enhancement as compared to the base liquid solution. In conclusion, optimum ratios for G-Al2O3 hybrid nanolubricants were determined to be 20:80 and 60:40. Regarding the properties enhancement ratio, the combination of enhanced thermophysical and tribological properties had more advantages for cooling lubrication application.

Comparative life cycle analysis of environmental and machining performance under sustainable lubrication techniques

One of the issues confronting manufacturers is the requirement for establishing sustainable production methods, which poise between economic feasibility and ecological preservation. Alternative sustainable cutting fluid methods must be developed since the traditional lubricants employed in machining operations are unsustainable from the environmental impact point of view. The balance between energy-production demand and quality-productivity is required for sustainable production. In this respect, this research studies the tool life, machining efficiency, energy consumption, and carbon emission under dry, flood machining, and minimum quantity lubrication machining. This study comprises two parts: evaluation of machining characteristics in terms of tool life, machining efficiency, energy consumption, and carbon emission, and the life cycle assessment (LCA) of inventories used during machining experimentation. The outcomes of this novel work revealed an increase of 42% and 61% in tool life at a cutting speed of 185 ​m/min under flood and MQL media than dry machining. At a cutting speed of 185 ​m/min in three different lubricating conditions, the percentage increase in the efficiency was 31%, and 28% for dry, flood, and MQL machining. In MQL machining, due to more uniform lubrication than flood machining, energy usage decreases by 38%, 32%, and 27% at the rate of metal removal of 93.67, 131.68, and 152.36 ​mm3/min. Also, A decrease in CO2 emissions of 16%, 21%, and 18% was attained in MQL machining than flood machining at 185, 215, and 245m/min cutting speeds. Furthermore, this also compares life cycle inventory analysis in dry, flood, and minimum quantity lubrication. Gate-to-gate approach methodology adopted for LCA analysis of system boundaries and functional unit to examine the environmental impression through ReCipe 2016, Endpoint (H) methodology. Sustainable assessment through life cycle analysis determined that dry and mist machining are more sustainable than wet machining.