Minimum Quantity Lubrication Mode Research Articles

Experimental investigation of nanofluid lubrication on surface roughness under MQL aluminum alloy 6061-T6 series in drilling

PurposeThis study aims to investigate the impact of varying the number of minimum quantity lubrication (MQL) nozzles, wind pressure, spindle speed and type of lubrication on surface roughness, fatigue life and tool wear in the drilling of aluminum alloy 6061-T6.Design/methodology/approachThe effect of using different lubricants such as palm oil, graphene/water nanofluid and SiO2/water in the MQL method was compared with flood and dry methods. The lubricant flow and feed rate were kept constant throughout the drilling, while the number of nozzles, wind pressure and spindle speed varied. After preparing the parts, surface roughness, fatigue life and tool wear were measured, and the results were analyzed by ANOVA.FindingsThe results showed that using MQL with four nozzles and graphene/water nanofluid reduced surface roughness by 60%, followed by SiO2 nanofluid at 56%, and then by palm oil at 50%. Increasing the spindle speed in MQL mode with four nozzles using graphene nanofluid decreased surface roughness by 52% and improved fatigue life by 34% compared to the dry mode. SEM results showed that tool wear and deformation rates significantly decreased. Increasing the number of nozzles caused the fluid particles to penetrate the cutting area, resulting in improved tool cooling with lubrication in all directions.Originality/valueNumerous attempts have been made worldwide to eliminate industrial lubricants due to environmental pollution. In this research, using nanofluid with wind pressure in MQL reduces environmental impacts and production costs while improving the quality of the final workpiece more than flood and dry methods.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2024-0021/

Surface integrity evaluation in ecological nanofluids assisted grinding of Inconel 718 superalloy

Surface integrity is an important term that describes the surface behaviour of a ground component. Grinding is defined as a finishing operation that has high specific energy consumption. High heat generation while grinding, adversely affects the surface integrity of the ground surfaces. With the development of advanced materials such as superalloys, this process is widely used in bulk machining for making critical components used in dynamic loading. Therefore, it becomes necessary to investigate the surface integrity of the ground components, as their surface integrity primarily determines their performance and durability. The purpose of this work is to enhance the grinding performance of Inconel 718, a difficult-to-grind material, by employing silver and zinc oxide (ZnO)-based ecological nanofluids in a minimum quantity lubrication (MQL) mode. The grinding parameters such as wheel speed and table speed are kept constant with variations in the grinding infeed. The grinding performance in terms of grinding forces, apparent coefficient of friction, surface roughness and residual stresses on the ground surfaces have been investigated. Skewness, kurtosis and the Abbott–Firestone curve have also been analysed using two-dimensional and three-dimensional plots for an in-depth study of ground surface behaviour. The finding suggests that ZnO-based nanofluid outclass the silver-based nanofluid using MQL mode in terms of reduced grinding forces and favourable residual stress. Therefore, it appears as the potential grinding environment for the improved grinding performance of Inconel 718.

Performance Evaluation of MQL with Graphene Mixed Nano Fluids prepared at different Concentrations in Turning of Pure Titanium (TI6Al4V) Alloy

This paper presents an investigation into the minimum quantity lubrication mode with Nano fluid during turning of titanium (TI6AL4V) alloy. In heavy cutting conditions, minimum quantity lubrication (MQL) has been observed, that, Nano-cutting fluids which have enrich thermal conductivity than base fluid, are begun to be used in MQL system. The addition of the required nano particle ratio to the base liquid is one of the most important issues that arise in this method. Therefore, this study aimed to find the optimum distribution rate of graphene nano particles having excellent properties and machining parameters. To do this, graphene nano particles were added to a vegetable-based cutting solution. Nano-cutting fluids were prepared in different volumetric concentrations. When turning of titanium (TI6AL4V) alloy, these Nano fluids were used in the MQL system. Three different parameters were added to the experimental design to study the performance of Nano fluids under several cutting conditions. i.e., speed, feed rate and depth off cut. Apart from this experimental design, three tests were carried out at each concentration ratio while keeping the machining parameters constant to clearly see the impact of concentration rates on surface roughness, flank wear. And crater wear. In addition, while chipping/fracture, were observed under all cutting conditions

Effect of turning environments and parameters on surface integrity of AA6061-T6: experimental analysis, predictive modeling, and multi-criteria optimization

The present research investigates the effect of turning environments and parameters on surface integrity induced by turning of AA6061-T6. Specifically, the evolution of turning parameters of cutting speed, feed rate, and depth of cut was studied under dry, minimum quantity lubrication (MQL), and wet environments and their impact on surface roughness and residual stresses, as critical parameters for surface integrity, were quantified. Machining tests were carried out using a design of experiment (DoE) based on central composite design (CCD) under the three turning environments. The most effective turning parameters were identified for each environment using analysis of variance (ANOVA). Response surface method (RSM) was used to predict effective regression models for each turning environment for the average arithmetic surface roughness, the height peak from the valley, the axial surface residual stress, and the hoop surface residual stress. Then, using the predictive regression models, a multi-objective optimization study was performed to determine optimal turning parameters in each environment for improved surface integrity in low speed turning (LST) and high speed turning (HST) of AA6061-T6. The results showed that feed rate and cutting speed were the most effective parameters on surface integrity. It was also found that better surface integrity and higher material removal rate (MRR) were achieved using MQL mode, which is an environmental friendly and cost-saving turning environment.

Tribological characteristics and micromilling performance of nanoparticle enhanced water based cutting fluids in minimum quantity lubrication

Friction and wear characteristics of water-based nanofluids were studied. Deionized water-based nanofluids were prepared with alumina (Al2O3), hBN, MoS2, and WS2 nanoparticles. Tribological study of the prepared nanofluids was undertaken on a ball-on-disk tribometer in minimum quantity lubrication (MQL) mode on Ti-6Al-4 V workpiece. The effect of flow rate on the coefficient of friction (μ) and wear of the workpiece was reported for different nanofluids. 3D profiles of the wear tracks were obtained to study the wear depth and wear profile. Alumina-based nanofluids have shown excellent performance in terms of friction and wear as compared to the other nanofluids. The coefficient of friction, wear track depth and specific wear were reduced by 53.89 %, 23.4 %, and 37.03 % respectively for alumina nanofluid in MQL mode as compared to the dry environment. A commercial cutting fluid (UNILUB 2032) was used for comparative studies. The commercial cutting fluid performed slightly better than the alumina nanofluid, both used in MQL mode. Even though hBN, MoS2, and WS2 are solid lubricants, their performance as nanofluids in MQL mode was not better than alumina nanofluids. Alumina particles, being spherical shaped, were able to provide better lubrication owing to the ball-bearing effect. Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) of the wear tracks were conducted to understand the mechanism of friction and wear reduction. Micromilling experiments were done on Ti-6Al-4 V using the prepared cutting fluids in MQL mode to evaluate their effect on machining forces and burr formation. Alumina nanofluids and the commercial lubricant have shown significant reduction in machining forces and burr formation as compared to the other nanofluids. This is in correlation to the tribological performance of these cutting fluids.

Evaluation of surface roughness and optimization of cutting parameters in turning of AA2024 alloy under different cooling-lubrication conditions using RSM method

In the present study, the effect of reduction of cutting fluid consumption on the surface quality and tool wear was studied. Mathematical models were developed to predict the surface roughness using response surface methodology (RSM). Analysis of variance (ANOVA) was used to investigate the significance of the developed regression models. The results showed that the coefficient of determination values (R2) for the developed models was 97.46% for dry, 89.32% for flood mode (FM), and 99.44% for MQL, showing the high accuracy of fitted models. Also, under the minimum quantity lubrication (MQL) condition, the surface roughness improved by 23%–44% and 19%–41% compared with dry and FM, respectively, and the SEM images of machined surface proved the statement. The prepared SEM images of tool rake face also showed a considerable decrease in adhesion wear. Built-up edge and built-up layer were the two main products of the adhesion wear, and energy-dispersive X-ray spectroscopy (EDX) analysis of specific points on the tool faces helped to discover the chemical compositions of adhered materials. By changing dry and FM to MQL mode, dominant mechanism of tool wear in machining aluminum alloy was significantly decreased. Breakage wear that led to early failure of cutting edge was also controlled by MQL technique.

Experimental study of oil mist characteristics generated from minimum quantity lubrication and flood cooling

Abstract The use of metalworking fluids during machining can generate oil mist and endanger the health of workers. In order to study the characteristics and emission laws of oil mist generated by machining, this study constructed a test bench to simulate the turning process. Parameters affecting the oil mist generated in the minimum quantity lubrication (MQL) mode and flood cooling mode were studied by means of single-factor experiments, and the formation mechanisms of oil mist were analyzed. The results show that the oil mist generated by the MQL system has two main sources, the initial escape of oil mist into the air and the evaporation/condensation of oil mist. The centrifugation has almost no effect on oil mist formation in the MQL mode. The mass concentration of oil mist generated by the MQL system is proportional to the cutting oil flow rate. When the work-piece is at room temperature, increasing the air supply pressure and nozzle distance, increases the oil mist mass concentration. For the flood cooling mode, the concentration of centrifugal aerosol is linearly and positively correlated with the relative centrifugal force generated by the work-piece, and the coefficient of determination (R2) is above 0.97. The oil mist mass concentrations in MQL mode is 8.33 mg/m3~ 305.88 mg/m3. The MMD and SMD are 0.74 µm to 4.42 µm and 0.31 µm to 2.14 µm, respectively. The oil mist mass concentrations in flood cooling mode is 0.2 mg/m3~ 22.42 mg/m3. The MMD and SMD are 1.81 µm to 6.58 µm and 0.45 µm to 5.13 µm, respectively.

Multi-Response Optimization of Turning Parameters during Machining of EN-24 Steel with SiC Nanofluids Based Minimum Quantity Lubrication

In manufacturing industry, the expenses for cutting fluids are about 7 to 17% of total production cost. The cutting fluids increase the health hazards as well as can cause a lot of environmental problems. In order to eliminate the ill effects associated with cutting fluids, it is now becoming necessary to move towards more sustainable techniques. To improve the surface quality of product and to minimize the expenditure of energy and resources it is essential to do optimization of turning parameters under sustainable cooling technique. For that purpose, grey relational analysis (GRA) proves to be a superior optimization technique to forecast and decision-making in various areas of manufacturing sector. In this research work, minimum quantity lubrication (MQL) setup has been developed and utilized for the experimentation. The nanofluids were prepared by adding the silicon carbide (SiC) nanoparticles (NPs) to the soluble oil with different weight percentages (0.5 wt.%, 1 wt.%, 1.5 wt.%). The thermal and tribological properties of SiC nanofluids were analyzed. Comparative analysis of MQL and SiC nanofluids based MQL turning has been done. Experimental results revealed that, the turning performance under SiC based nanofluids MQL mode is better as compared to MQL. The experimentation was planned as per Taguchi methodology. GRA has been employed to optimize the process parameters during turning of EN-24 steel under SiC based nanofluids MQL environment for better machining performance characteristics. The turning parameters under SiC based nanofluids MQL environment were optimized by GRA to obtain improved surface quality. The results revealed that optimization through GRA enhance output quality characteristics.

Surface integrity in grinding of Ti-6Al-4V using monolayer superabrasive wheel

ABSTRACTTitanium alloy is considered to be difficult to grind due to its low thermal conductivity, relatively high grinding temperature and its reactivity with almost all grit materials. Residual stress on the ground surface, which is one of the major aspects of surface integrity, has not been studied well in case of grinding of Ti- alloys. Further, investigations assessing the effectiveness of emulsion of vegetable oil in water as a grinding fluid applied in minimum quantity lubrication (MQL) mode are lacking. The present work endeavours to experimentally study the effect of different grinding fluids applied in MQL mode in comparison to flood cooling with soluble oil on different grindability characteristics with particular emphasis on residual stress. Neat oil, applied in MQL mode, has provided a reduction in grinding forces, even in comparison to flood cooling. It has also yielded overall competitive performance in comparison to flood cooling from the perspective of surface roughness, residual stress, and ground surface topography.

Optimization of Process Parameters based on Surface Roughness and Cutting Force in MQL Turning of AISI 4340 using Nano Fluid

The aim of this research work is focused on optimization of process parameters under Minimum Quantity Lubrication (MQL) using nano fluid in turning of AISI 4340. A study of effect of process parameters in turning of AISI 4340 under MQL condition with nano fluid (Multiwalled Carbon Nano Tube) on the cutting force generated and machined surface roughness is carried out. In the experiment conducted, five values of feed rate, three values of depth of cut, two values of cutting speed and tool nose radius respectively, are used. The test pieces were turned on a CNC lathe machine under MQL mode using nano fluid with different levels of process parameters by using full factorial design of experiment orthogonal array. The surface roughness of the machined surface was measured using surface measurement tester. Taguchi methodology was used to optimize process parameters. The results were analyzed by using Analysis of variance. From result analysis, it was found that, feed rate played a major role in producing lower surface roughness followed by depth of cut whereas cutting speed has least significance in producing lower surface roughness under MQL using nano coolant. It was observed that MQL with nano fluid (MWCNT) showed lowest surface roughness as compared to conventional flood system. Thus, with proper selection of process parameters under MQL mode with nano coolant, it is possible to achieve good surface roughness, reduce tool wear while maintaining the cutting forces and temperatures at reasonable levels.

Parametric Optimization Of Minimum Quantity Lubrication In Turning Of AISI 4340 Using Nano Fluids

Modern machining industries demand for improved surface roughness from micro level to nano level along with increased tool life and reduced cutting temperature and force during machining. Therefore, the aim of this research work is focused on optimization of Minimum Quantity Lubrication (MQL) parameters using nano fluids in turning of AISI 4340. A study of effect of MQL parameters on the surface roughness of AISI 4340 was carried out using nano fluid such as Multi Walled Carbon Nano Tube (MWCNT). In the experiment conducted, four values of pressure, four values of flow rate and two types of nano fluids were used. The chemical composition of the work material was tested using arc spectrometer and verified to be of grade AISI 4340. The test pieces were turned on a CNC lathe machine under MQL mode using nano fluid with different levels of MQL parameters by using Taguchi L16 orthogonal array. The surface roughness of the machined surface was measured using surface measurement tester. Taguchi methodology was used to optimize MQL parameters. The results were analyzed using Analysis of Variance (ANOVA). From result analysis, it was shown that, cutting fluid (Nano fluid) played a major role in producing lower surface roughness followed by flow rate whereas pressure has least significance in producing lower surface roughness under MQL using nano coolant. It was observed that ethylene glycol with nano fluid (MQL1) showed lowest surface roughness as compared to water with nano fluid (MQL2). The optimum condition under MQL mode with nano fluid obtained as pressure (5 bar), flow rate (140 ml/hr.) and cutting fluid type 1. From result analysis it is also observed that, ethylene glycol as a base fluid with nano fluid is a most significant factor affecting surface roughness. The percentage error between experimental and predicted surface roughnesses is below ±10%. Thus, with proper selection of MQL parameters and nano coolant, it is possible to achieve good surface roughness, reduce tool wear while maintaining the cutting forces and temperatures at reasonable levels.

Prediction of surface roughness and cutting force under MQL turning of AISI 4340 with nano fluid by using response surface methodology

This paper presents an investigation into the minimum quantity lubrication mode with nano fluid during turning of alloy steel AISI 4340 work piece material with the objective of experimental model in order to predict surface roughness and cutting force and analyze effect of process parameters on machinability. Full factorial design matrix was used for experimental plan. According to design of experiment surface roughness and cutting force were measured. The relationship between the response variables and the process parameters is determined through the response surface methodology, using a quadratic regression model. Results show how much surface roughness is mainly influenced by feed rate and cutting speed. The depth of cut exhibits maximum influence on cutting force components as compared to the feed rate and cutting speed. The values predicted from the model and experimental values are very close to each other.

Influence of nanofluid application on wheel wear, coefficient of friction and redeposition phenomenon in surface grinding of Ti-6Al-4V

Difficulties in the grinding of Ti-6Al-4V originate from the three basic properties: poor thermal conductivity, high chemical reactivity and low volume specific heat of the material. Under severe grinding conditions, all these factors together lead to the accelerated wheel loading and redeposition of chips over the work surface. Redeposition and wheel loading have a significant effect on the surface finish, grinding forces, power consumption and wheel life. In this study, water-based Al2O3 nanofluid as metalworking fluid is applied during the surface grinding of Ti-6Al-4V under minimum quantity lubrication mode after dressing the wheel with different dressing overlap ratios. The severity of the redeposition over the work surface was observed by measuring various surface profiles taken perpendicular to the grinding direction at several locations on the ground surface. The nanofluid application was able to prevent redeposition over work surface that became evident from the measured surface finish parameters that results along the grinding direction. Coefficient of friction was estimated On-Machine using the measured forces for different wheel work speed ratios, depth of cut and dressing overlap ratios. The results showed the effectiveness of nanofluid in reducing friction at high material removal rate (i.e. high depth of cut and high speed ratio) conditions when compared to the dry environment. From the measured forces variation with respect to the number of passes, it became evident that, nanofluid application delayed the frequency of wheel loading and grit fracturing cycle, which leads to the increase in the wheel life.

An investigation into the application of Al<SUB align="right">2O<SUB align="right">3nanofluid-based minimum quantity lubrication technique for grinding of Ti-6Al-4V

Nanofluids, suspensions of nanoparticles in base fluid, has shown attractive cooling and lubricating properties. The nano–coolants and nano–lubricants find applications in a wide variety of materials processing technologies. It is anticipated that, if properly employed, nanofluids usage could surpass the conventional cutting fluids in the future. Minimum quantity lubrication (MQL) technique also, has achieved a significant consideration in manufacturing processes to minimise the environmental loads caused by the usage of traditional cutting fluids. The aim of this work is to examine the potential of Al2O3 nanofluid under MQL mode to improve the grinding characteristics of Ti–6Al–4V alloy. 1% Volume concentration of water–based Al2O3 nanofluid was applied during the surface grinding operation using an indigenously developed MQL setup and the results have been compared with those of conventional coolant under both flood cooling and MQL mode.

Application of Nano Cutting Fluid under Minimum Quantity Lubrication (MQL) Technique to Improve Grinding of Ti – 6Al – 4V Alloy

Minimum Quantity Lubrication (MQL) technique obtained a significant attention in machining processes to reduce environmental loads caused by usage of conventional cutting fluids. Recently nanofluids are finding an extensive application in the field of mechanical engineering because of their superior lubrication and heat dissipation characteristics. This paper investigates the use of a nanofluid under MQL mode to improve grinding characteristics of Ti-6Al-4V alloy. Taguchi’s experimental design technique has been used in the present investigation and a second order model has been established to predict grinding forces and surface roughness. Different concentrations of water based Al2O3 nanofluids were applied in the grinding operation through MQL setup developed in house and the results have been compared with those of conventional coolant and pure water. Experimental results showed that grinding forces reduced significantly when nano cutting fluid was used even at low concentration of the nano particles and surface finish has been found to improve with higher concentration of the nano particles. Keywords—MQL, Nanofluid, Taguchi method, Ti-6Al-4V.

Effect of cooling and lubrication conditions on surface topography and turning process of C45 steel

At present coolants and lubricants are increasingly recognized as harmful factors for environment and machine operators’ health. Industry and research institutions are looking for new means of reducing or eliminating the use of cutting fluids, both for economical and ecological reasons. This can be done if quality properties of machined surfaces and process parameters in dry and wet machining are comparable. This paper presents an investigation into the influence of cutting zone cooling and lubrication on surface roughness, waviness, profile bearing ratio and topography after turning C45 steel. Dry cutting and minimum quantity lubrication (MQL) results are compared with conventional emulsion cooling. Cutting forces and their components were put under examination as well. The experimental outcomes indicate that the cooling and lubrication conditions affect significantly the investigated process and surface properties. However, the impact of the cooling and lubricating technique depends to a large extent on the applied cutting parameters, namely the cutting speed and feed rate. Turning dry or with MQL with properly selected cutting parameters makes it possible to produce better surface topography characteristics than turning with conventional emulsion cooling. Apart from improving the surface properties the MQL mode of cooling and lubrication also provides environmental friendliness.