Minimum Quantity Lubrication Method Research Articles

An Experimental Investigation of the Effects MQL Using Nanofluids on Surface Roughness of Hard Milling Process

High cutting force and cutting heat are challenging problems that need to be overcome for the hard milling process. Minimum quantity lubrication (MQL) has been shown to be effective and suitable for use in hard milling due to the improving lubrication in the cutting zone. The content presented in this article is to investigate MQL using emulsion cutting oil with/without Al2O3 nanoparticles for hard milling of 60Si2Mn steel (50-52 HRC) using carbide tools. Factorial experimental design is used to evaluate the cooling condition, cutting speed and feed rate on surface roughness. Experimental results show that feed rate has the greatest influence on surface roughness among the parameters investigated, followed by cooling mode and cutting speed. MQL technique using nano cutting oil gives better machined surface quality than MQL using pure cutting oil, which has proven that the additives of Al2O3 nanoparticles to the base cutting oil has improved cooling and lubrication capability. Furthermore, the applicability of MQL method is expanded to apply for hard milling.

Enhancing machining efficiency of Ti-6Al-4V through multi-axial ultrasonic vibration-assisted machining and hybrid nanofluid minimum quantity lubrication

Ti-6Al-4V offers a balance of good strength with lightweight properties. Yet, Ti-6Al-4V poses machining challenges, including low thermal conductivity, chemical adhesion to cutting tools, and chip removal difficulties. To improve machining efficiency, Ultrasonic Vibration-Assisted Machining (UVAM) has emerged as a promising approach. UVAM has demonstrated reduced tool wear, cutting forces, and improved surface quality compared to Conventional Machining (CM). Additionally, Minimum Quantity Lubrication (MQL) methods offer sustainable coolant alternatives, with recent research focusing on Nanofluid-MQL (NMQL) and Hybrid Nanofluid-MQL (HNMQL) for enhanced performance. Although there exists a body of literature showcasing the promising effects of UVAM and MQL methods individually, comprehensive investigations into the synergistic effects of these methodologies remain limited. This study addresses these critical research gaps by conducting a systematic examination of combined application of multi-axial UVAM and HNMQL. Specifically, it delves into the comparison of different vibration directions within UVAM, evaluates the effectiveness of UVAM when combined with cutting fluids incorporating Al2O3 and CuO nanoparticles in NMQLs and HNMQLs, and contrasts these novel approaches with conventional machining methods. The study unfolds in three distinct stages. The first stage examines the ultrasonic cutting mechanism and its combined application with the MQL technique. In the second stage, the study investigates the physical properties of the cutting fluids, including contact angle and surface tension. The final stage encompasses slot milling operations, where an array of parameters such as cutting forces, surface roughness, surface topography, surface texture, and the occurrence of burr formations are rigorously analyzed. The results demonstrate that the combination of multi-axial UVAM with HNMQL yields substantial advantages over traditional machining methods. Notably, it leads to a remarkable reduction in cutting forces (up to 37.6 %) and surface roughness (up to 37.4 %). Additionally, this combination engenders the production of highly homogeneous and uniform surface textures, characterized by minimal surface defects and a significantly diminished occurrence of burr formations. These findings underscore the potential of multi-axial UVAM combined with HNMQL as a promising approach in enhancing the machining of Ti-6Al-4V, thus offering a pathway to enhance the efficiency and precision of aerospace component manufacturing processes.

Investigation of the Effects of Cutting Fluid Application with Minimum Quantity Lubrication (MQL) Method on the Machinability of Pure Titanium

Machining is one of the widely used methods in today's technology and there are many parameters that affect the machinability of the produced product. In the machining process, the machinability of the product depends on parameters such as feed rate, depth of cut, cutting speed and cutting fluid. The use of cutting fluid during the process has advantages such as improving surface quality, but also disadvantages such as increased cost and environmental damage. Due to these disadvantages of cutting fluid in manufacturing processes, alternative methods have been developed. The method called minimum quantity lubrication (MQL) not only reduces cost but also improves machinability. In this study, the machinability of titanium turning was evaluated with main cutting force, surface roughness and temperature measured in the primary cutting zone data. MQL method was used in the study and Taguchi L9 model was applied. The results were compared between dry cutting and MQL atmospheres. The reliability of the data and the degree of influence of the parameters were analyzed by ANOVA. In this study, the shear force data obtained in the dry shear atmosphere were higher than the data obtained in the MQL method. In addition, the surface roughness values obtained in dry cutting atmosphere were also relatively high. The optimum cutting speed, feed rate and depth of cut values for the process were determined as 60 m/min, 0.05 mm/rev and 0.5 mm, respectively.

Effects of Machining Parameters on Total Cutting Force in Hard Turning Process of Hardened 90CrSi Steel Using Carbide Insert with MoS2 Nanofluid MQL

Minimum Quantity Lubrication (MQL) is widely used in machining, especially hard machining. However, this method has many limitations regarding cooling and lubrication capabilities. In recent years, nano-cutting oils have been researched and applied in machining to improve the lubrication and cooling efficiency of the MQL method. In this research, the machinability of 90CrSi steel with carbide inserts using nanofluid with different concentrations (1%, 1.5%, and 3%) of molybdenum disulfide (MoS2) nanoparticles in emulsion oil was evaluated by applying Box-Behnken optimization model. Carbide inserts commonly used to machine the low hardness steel (below 35HRC) have been used to cut hardened steel with high hardness (59-62HRC) by applying the MQL technology with MoS2 nanofluid. A mathematical model was also used to predict the cutting resultant force value in the hard turning process under MQL conditions using MoS2 nanofluid. The obtained results indicate that the total cutting force reached the minimum value (328 N) with the MoS2 nanoparticle concentration of 1.985%, a cutting speed of 80 m/min, and a feed rate of 0.138 mm/rev. In particular, the work has also provided technical guides for different machining conditions.

PENGARUH PENGGUNAAN MINYAK JAGUNG UNTUK CUTTING FLUID PADA PROSES FACE MILLING TERHADAP KEKASARAN PERMUKAAN PERMUKAAN DAN LAJU KOROSI BAJA KARBON

The corrosive coastal environment will result in a high corrosion rate for any equipment installed there. This is due to the constant exposure to saltwater, high humidity levels, and strong winds. Therefore, it is crucial to use corrosion-resistant materials and regularly maintain the equipment to ensure its longevity in such an environment. One method to reduce the rate of corrosion is to pay close attention to the manufacturing parameters of these components, one of which is the face milling process. The aim of this study is investigating the effect of face milling process with different dept of cut using minimum quantity lubrication method with corn oil as a renewable vegetable cutting fluid. In this study AISI 316L stainless steel was face milled using HAAS VF-2 CNC machine. The depth of cut is varied between 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, and 0.6 mm. The results demonstrated that the greater the depth of cut, the greater the surface roughness value that will be generated. It is resulting in increment in the corrosion rate value.

Analysis of Power Grid Parameters Depending on the Variable Concentration and Size of Copper Nanoparticles and Aerosol Formation Parameters in the Minimum Quantity Lubrication Method During Turning of Ti6Al4V Titanium Alloy

Analysis of Power Grid Parameters Depending on the Variable Concentration and Size of Copper Nanoparticles and Aerosol Formation Parameters in the Minimum Quantity Lubrication Method During Turning of Ti6Al4V Titanium Alloy

An Experimental Study on Ultrasonic Vibration-Assisted Turning of Aluminum Alloy 6061 with Vegetable Oil-Based Nanofluid Minimum Quantity Lubrication

Minimum quantity lubrication (MQL) is a potential technology for reducing the consumption of cutting fluids in machining processes. However, there is a need for further improvement in its lubrication and cooling properties. Nanofluid MQL (NMQL) and ultrasonic vibration-assisted machining are both effective methods of enhancing MQL. To achieve an optimal result, this work presents a new method of combining nanofluid MQL with ultrasonic vibration assistance in a turning process. Comparative experimental studies were conducted for two types of turning processes of aluminum alloy 6061, including conventional turning (CT) and ultrasonic vibration-assisted turning (UVAT). For each turning process, five types of lubricating methods were applied, including dry, MQL, nanofluid MQL with graphene nanosheets (GN-MQL), nanofluid MQL with diamond nanoparticles (DN-MQL), and nanofluid MQL with a diamond/graphene hybrid (GN+DN-MQL). A specific cutting energy and areal surface roughness were adopted to evaluate the machinability. The results show that the new method can further improve the machining performance by reducing the specific cutting energy and areal surface roughness, compared with the NMQL turning process and UVAT process. The diamond nanoparticles are easy to embed on the workpiece surface under the UVAT process, which can increase the specific cutting energy and Sa as compared to the MQL method. The graphene nanosheets can produce the interlayer shear effect and be squeezed into the workpiece, thus reducing the specific cutting energy. The results provide a new way for the development of eco-friendly machining.

Sustainability assessment and optimization for milling of compacted graphite iron using hybrid nanofluid assisted minimum quantity lubrication method

The climate change packages have strict regulations to reduce fuel consumption, costs, and carbon emissions in vehicles. Automobile manufacturers tend to utilize compacted graphite iron (CGI) in vehicle engine parts due to these regulations and rising engine performance needs. However, the difficulty of CGI machining and the sustainability problem during machining are barriers to its broad application in the automobile sector. In this study, nano molybdenum disulfide (nMoS2) reinforced nanofluid-assisted MQL (nMoS2-NMQL), multi-walled carbon nanotube (MWCNT) reinforced nanofluid-assisted MQL (MWCNT-NMQL) and nMoS2/MWCNT reinforced hybrid nanofluid-assisted MQL (HNMQL) cutting conditions were used for the first time in the milling of CGI material and machining performance was investigated in terms of cutting forces, cutting temperature and surface roughness. In addition, for the first time in the milling of CGI material, sustainability assessment and optimization in terms of carbon emissions and total machining cost have been carried out using non-dominant sequencing genetic algorithm II (NSGA-II) and technique for order of preference by similarity to ideal solution (TOPSIS). Using the MWCNT-NMQL cutting condition reduced the cutting temperature, resultant force, surface roughness, carbon emissions amount, and total machining cost by 38.2%, 54.5%, 57.6%, 7.6%, and 24%, respectively. The sustainability optimization conclusion was that MWCNT-NMQL cutting condition, cutting speed values between 90 and 93 m/min, and feed values between 0.11 and 0.117 mm/rev should be used in order to obtain the values closest to the optimum result for an improved and sustainable CGI milling process.

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.

Investigation of the surface quality and machinability of AISI 316LVM

Surface quality has a significant effect on the reliability of an implant. The surface finish of the workpiece is influenced by machining parameters, tool wear and cooling–lubrication conditions. Typically, mineral oil-based conventional cutting fluids are employed for cooling and lubricating purposes in industrial machining processes. However, the use of these fluids places costly environmental and health responsibilities on companies. Consequently, it is preferable to utilize an affordable and environmentally friendly coolant/lubricant that does not generate liquid waste or have harmful side effects. In this work, we conducted experimental investigations to examine the effect of cutting forces, cutting temperature, tool wear and the quality of the machined surface on the machinability performance of medical grade AISI 316LVM austenitic stainless steel. Five different cutting conditions were employed in the machining experiments: dry cutting, flood, minimum quantity lubrication (MQL), cryogenic cutting with liquid carbon dioxide (LCO2) and cryogenic cutting with liquid nitrogen (LN2). Compared to the dry-cutting condition, the cutting temperature decreased by 42.1% under LN2 and flood conditions and by 40.4% under LCO2 conditions. The cutting tools exhibited small amounts of flank wear and nose wear, along with the formation of built-up edges (BUE); however, no crater wear was observed. The MQL method resulted in the lowest cutting forces, while the cryogenic methods yielded the highest cutting forces. Among the cutting conditions, the MQL and flood conditions produced the lowest roughness values and the best surface quality. Conversely, the cryogenic cutting conditions led to the highest roughness values and the poorest surface quality. Furthermore, the MQL condition resulted in the lowest dimensional deviations.

Mechanism and enhanced grindability of cryogenic air combined with biolubricant grinding titanium alloy

Grinding is an essential method for ensuring the machining accuracy and surface quality of difficult materials, such as aerospace titanium alloys. However, the deterioration of workpiece surface integrity due to thermal damage is the technical bottleneck of titanium alloy grinding. Therefore, a new enabling grinding technology for cryogenic air combined with a biolubricant is proposed. The introduction of cryogenic air leads to fundamental changes in the physical properties and lubrication mechanism in the grinding zone. On this basis, the formulas between the cryogenic air temperature and biolubricant temperature, kinematic viscosity, and surface tension coefficient are established. Under the same grinding parameters, compared with dry grinding, the normal force, tangential force, specific grinding energy, friction coefficient, temperature, and surface roughness value of cryogenic air minimum quantity lubrication decrease by 47.6%, 44.3%, 45.1%, 19.8%, 43.9%, and 46.3%, respectively. Then, the influence law of single and multiple factors on the grinding effect is discussed. When the peripheral speed, feed speed, and grinding depth are 30 m/s, 6 mm/s, and 30 µm, the optimal combination of factor parameters is a cryogenic air temperature of − 50 °C, an air pressure of 0.4 MPa, and nozzle inclination angle of 16°. Furthermore, on the basis of the multifactor orthogonal experiment, the quantitative mapping relationship between different grinding and influence factors is investigated to achieve optimal workpiece surface quality. This research provides a new effective method for improving the high surface integrity of grinding titanium alloys by using the cryogenic air minimum quantity lubrication method.

Orthogonal turning of AISI 310S austenitic stainless steel under hybrid nanofluid-assisted MQL and a sustainability optimization using NSGA-II and TOPSIS

AISI 310S austenitic stainless steels are widely used in many industries, such as oil, gas, and petrochemical industries containing hot concentrated acids, due to their superior properties like corrosion resistance, high-temperature service, and creep resistance. However, a study on the machining of AISI 310 stainless steel has not been published in the scientific literature. It is known that the machinability of the austenitic stainless steel alloys, in which the AISI 310S alloy is included, is poor due to its low thermal conductivity, high work hardening, and built-up edge (BUE) formation. This situation causes sustainability problems by increasing the energy consumptions, the total machining cost and the amount of carbon emissions. The presented study investigated for the first time machining response and sustainability assessment in the orthogonal turning of AISI 310S stainless steel using three different cutting speeds and feed values, and five different cutting conditions such as dry, vegetable-based fluid minimum quantity lubrication (MQL), nano molybdenum disulfide (nMoS2) reinforced nanofluid MQL, nanographene (nGP) reinforced nanofluid MQL, and nMoS2/nGP reinforced hybrid nanofluid MQL, and a sustainability optimization was performed. Sustainability optimization was conducted to minimize the resultant force, surface roughness, carbon emission, and total machining cost using multi-objective optimization with NSGA-II (Non-dominated Sorting Genetic Algorithm II) and multi-criteria decision-making with TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution). The resultant force, surface roughness, total carbon emission, and total machining cost were reduced by a significant, 56.8%, 86.8%, 30.4%, and 2.9%, respectively, under the nGP reinforced nanofluid MQL cutting condition compared to the dry cutting condition. As a result of sustainability optimization, the use of high cutting speed (220 m/min), low feed values (between 0.11 mm/rev and 0.14 mm/rev), and nGP reinforced nanofluid MQL method (N2-MQL) in the turning of AISI 310S stainless steel material provides the optimum surface roughness values, cutting forces, carbon emissions, and total machining costs.

An investigation on performance of castor oil and Pongamia oil based cutting fluid in MQL milling of aluminium alloy 6061

The expense of coolant in milling processes accounts for such a significant portion of overall production costs, research efforts are presently concentrated on finding ways to reduce or do away with the need for lubrication. The environment, the performance of the machining, and the prices of the machining can all benefit from the decrease or elimination of traditional fluid. By employing the Minimum Quantity Lubrication Method, one is able to cut down on lubrication costs while also lowering the potential danger to the health of workers. While end milling aluminium 6061 with a SINOMILL VMC300 and an HSS end mill tool at three distinct spindle speeds (1000, 1500, and 2000 rpm), three distinct doc(0.25, 0.5, and 0.75 mm), and three distinct feed(100,150,200 mm/min), surface roughness (Ra) was measured in dry milling, MQL with base fluid (Pongamia oil, castor oil), conditions. The reduction in Ra is reported as a 12.89% with base fluid (Pongamia oil), in comparison to dry milling. When compared to dry milling, the reduction in Ra that was recorded when using base fluid (castor oil) was 33.72%. In this experiment it was carried out by the Drop shape analyzer (which was manufactured by Kruss), it was found that the contact angle in castor oil is superior to the contact angle in pongamia oil, and the values of contact angle are 43.4 and 47.8 respectively.

Investigation on the effect of hybrid nanofluid in MQL condition in orthogonal turning and a sustainability assessment

The installation of cost- and energy-efficient chip removal processes is the key point for sustainability. In the literature, many sustainability assessments have been made for minimum quantity lubrication (MQL) and mono nanofluid-assisted MQL (N-MQL) methods, considering energy consumption and costs. However, there are deficiencies in the assessment of sustainability in terms of machining cost and carbon emission amount in studies using the hybrid nanofluid MQL (HN-MQL) method. In the presented study, the Taguchi experiment design was established with different cutting conditions (dry, MQL, 0.2% MWCNT nanoparticle reinforced N-MQL, 0.1% MWCNT+0.1% MoS2 nanoparticle reinforced HN-MQL), different cutting speeds (175, 225, 275 and 325 m/min), and different feed values (0.1, 0.15, 0.2 and 0.25 mm/rev) in the orthogonal turning of S235JR structural steel, and optimum cutting parameters were determined in terms of cutting temperature and cutting forces by ANOVA analysis. This was followed by the sustainability assessment of the experiments conducted to quantify the sustainability aspect of machining in terms of total machining costs and total carbon emissions. While assessing machinability parameters, it was found that the best results out of all the performed experiments for both cutting forces and cutting temperatures were obtained under N-MQL conditions. It was determined that the most effective parameter on cutting force and thrust force was feed with 86.8% and 65% contribution ratios, respectively, and cutting conditions had the most effect on cutting temperature with 93.2% contribution ratio. The total machining cost were lowered by significant amount (up to 76%, 73% and 61% in comparison with dry, MQL and HN-MQL) under N-MQL cutting environment owing to the reduction in energy consumption and better tool life in comparison with other parameters. The overall carbon emissions were also most optimal (better by up to 60% and 37% in comparison with MQL and HN-MQL) under the N-MQL cutting environment in comparison with other cutting environments. The sustainable aspects of the machining process were enhanced more under higher cutting speeds than under lower cutting speeds.

Evaluation of Nano Fluids with Minimum Quantity Lubrication in Turning of Ni-Base Superalloy UDIMET 720

This article focuses on turning superalloy Udimet 720, which is difficult to work with, using different coolant/lubricant methods. The study includes delivering Graphene and Multi-Walled Carbon Nanotubes nanopowders homogeneously dispersed in vegetable oil to the cutting area with the minimum quantity lubrication (MQL) method. Experiments at different cutting speeds and feed rates were repeated in four different cutting environments. Compared to dry turning, the cutting zone temperature of the cutting fluid delivered to the cutting zone by MQL methods decreased. In addition, thanks to the nanopowders, it formed an oil film by better penetrating the cutting tool-chip interface and reducing the cutting tool’s wear. With the reduced cutting tool wear, the cutting tool could maintain its form for a longer period of time, so better quality surfaces were obtained on the workpiece surface. As a result of the study, it was found that cutting zone temperature improved by 30%, tool wear by 51.8% and surface roughness by 43.9%.

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.

Machinability Assessment of Hybrid Nano Cutting Oil for Minimum Quantity Lubrication (MQL) in Hard Turning of 90CrSi Steel

Friction and very high temperature are still the major challenges in hard machining technology and they greatly affect cutting efficiency. The application of the MQL (minimum quantity lubrication) method, using nanoparticles in order to improve the cooling lubrication performance of the base cutting oil, has proven to be a promising solution. Hence, this work aimed to investigate the effectiveness of Al2O3/MoS2 hybrid nanofluid and Al2O3 and MoS2 mono nanofluids in the hard turning of 90CrSi steel (60–62 HRC) under an MQL environment. The Box-Behnken experimental design was used for three input variables, including nanoparticle concentration, air pressure, and air flow rate. Their influences on surface roughness and cutting forces were studied. According to the obtained results, it was shown that the application of hybrid nano cutting oils in MQL contributes to achieving better hard machining performance than the use of mono nanofluids. In particular, a lower cutting temperature is reported and the values of surface roughness Ra, back force Fp, and cutting force Fc were smaller and more stable under Al2O3/MoS2 hybrid nanofluid MQL than those under Al2O3 and MoS2 mono nanofluid MQL due to an improvement in cooling lubrication characteristics. Thus, this work provides a novel approach to study hybrid nanofluids for MQL hard machining.

Utilization of Minimum Quantity Lubrication (MQL) Chip Fan on SS304 During Milling Process to Increase Carbide Tool Life

Minimum quantity lubrication (MQL) is the most used recent method in the milling process that is economical and environmentally friendly. The MQL method can reduce the temperature during the milling process. The high temperature that occurs in the carbide tool will affect the tool’s life. The use of cooling fluid is a common method to reduce high temperatures. However, the remaining cooling fluid has an impact on the pollution of the environment. Therefore, in this study, a novel approach for a cooling system based on the combined MQL method and fan cooling device was introduced and called an MQL Chip fan. The effect of the MQL Chip fan on the temperature, tool life, and surface roughness was investigated. The Taylor equation was used to calculate tool life based on temperature data from an experimental investigation. Subsequently, the quality inspection was conducted by using a surface roughness tester. The spindle speed and depth of cut have proven to make a great impact on the peak temperature, but, there is an optimal point where spindle speed made a turbulence and the tool had a passive cooling system. The utilization of the MQL Chip fan has decreased temperature by more than half at a medium speed of 2241 rpm and made a high contribution for low-speed processing and only a slight contribution for high-speed processing. Based on Tool Life prediction, 3600 RPM with a 3 mm depth of cut has more efficient performance compared to 2241 rpm with the same depth of cut. The utilization of the MQL Chip fan contributes significantly to the roughness value; the Ra value decreased from 1.374 μm to 0.461 μm. It has been proven that the utilization of an MQL Chip fan in the milling process reduces temperature and also increases the tool life.

Investigation of non-edible vegetable oil as cutting fluid in boring operation using MQL technique for CEW-1 steel

The cutting fluid plays a significant role by cooling the machining region and evacuating chips from the cutting area during the machining. However, using the traditional cooling approach has a negative impact on human health and the environment. Furthermore, it contributes for 18 to 20 % of the entire production cost in the manufacturing industry. To address this problem, minimum quantity lubrication (MQL) is outperforming traditional cooling method in terms of achieving a high-quality surface and better overall machining performance. In this study a number of trials has been taken to investigate the effect of process parameters on surface finish, circularity, cylindricity. The trials have been carried out on boing machine. Comparative study by using Neem oil, Karanja oil and convectional oil in boring operation by using MQL technique has been carried out. Comparative results encourage using MQL system along with Neem and Karanja oil in boring operation of CEW-1 steel. Although kaanja oil and conventional cutting fluids perform similarly, Neem oil outperforms during boring of “CEW 1” Grade Steel. Also it has been observed from experimental results that minimum quantity lubrication method performed better as compare to conventional flood system.

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.