Nano-cutting Fluids Research Articles

Machinability performance of bio-degradable hybrid nano-cutting fluid for sustainable manufacturing: analytical and soft computing modelling

Machinability performance of bio-degradable hybrid nano-cutting fluid for sustainable manufacturing: analytical and soft computing modelling

Performance assessment of graphene oxide based nano-cutting fluids during sustainable hard turning through synthesis, characterization and machinability investigation

Achieving sustainability in manufacturing necessitates the implementation of eco-friendly solutions by adopting environmentally friendly coolants with cost-effective, energy-efficient and cleaner production processes without posing any risk to the operator's health. In this current work, mineral oil-based graphene oxide (GO) nano-cutting fluids of different concentration (0.05, 0.1, 0.2, 0.3, 0.4, 0.5 % wt.) are synthesized and their characteristics such as rheological, thermo-physical and tribological properties along with their stability and toxicology impact are thoroughly investigated. Further, the influence of nano-cutting fluid concentration on machinability and sustainability aspects during hard turning such as flank wear, surface integrity, power consumption, cutting temperature, carbon and noise emissions are investigated. According to the result an enhancement of 28.83 % and 29.54 % in viscosity and thermal conductivity have been recorded when concentration of nanofluid increases from 0.05 % to 0.5 %. GO nano-cutting fluids shows anti wear and friction reduction properties by providing excellent lubricious properties, as a result coefficient of friction has been reduced up to 28.36 % at 0.5 % wt. GO compared to plane mineral oil. A notable reduction in flank wear, cutting temperature, surface roughness, cutting temperature, power consumption, carbon emission and noise emission were noticed to be 25.96 %, 27.82 %, 23.86 %, 25.22 %, 11.66 % and 2.72 % respectively when the concentration of GO nanoparticles increases from 0.05 % to 0.5 % wt. Smoother surface with minimal defect has been noticed from the SEM and AFM image of machined workpiece at highest concentration (0.5 % wt.) of GO due to the synergetic effect of GO nano-cutting fluid and dual nozzle MQL system.

Sustainable hard machining under zirconia nano-cutting fluid: A step towards a green and cleaner manufacturing process

The present study deals with the machinability (flank wear, surface integrity, cutting temperature and power consumption) and sustainability (Carbon emission and noise emission) investigations during hard machining under dual nozzle assisted novel ZrO2 based nano fluid MQL condition considering Taguchi L27 OA design of experiment. 0.3 % wt. ZrO2 nanofluid MQL medium effectively reduce cutting temperature and found as 65 °C, which shows the effective cooling and lubrication properties of zirconia nanofluid. Improvement in surface quality has been observed with lower rate of flank wear. Depth of cut and feed are found to be the most influential factor affecting power consumption and carbon emission with contribution of 47.213 % and 60.861 % respectively. Noise emission mostly affected by the depth of cut with a contribution of 43.40 %. Optimal parametric condition yields d: 0.1 mm, f: 0.1 mm/rev and v: 80 m/min through WASPAS and sustainable towards manufacturing industries for cleaner hard machining.

Hard turning performance assessment of AISI D2 steel under dual nozzle MQL assisted ZrO2 and GO nano-cutting fluids: A sustainability approach

“Green manufacturing” is often referred as a sustainable manufacturing process where ecofriendly cutting fluids are used to achieve social, economic, and environmental goals, which mitigates the soil, air, and water contamination and enhances operator’s health and safety. In this current study, mineral oil based ZrO2 and GO nano-cutting fluids are utilized for the cooling and lubrication purpose during the machining of hardened AISI D2 steel (55 ± 1 HRC). Machinability characteristics such as tool wear, surface roughness, cutting temperature, power consumption, and the span of the tool has been investigated in this study along with the sustainability aspects such as machining cost, carbon, and noise emissions during the machining process. Machining under GO nano-cutting fluid coupled with dual nozzle assisted MQL outperformed other environments such as ZrO2 NFMQL, pure mineral oil MQL and dry conditions in all aspects. The maximum tool life was achieved under GO NFMQL condition as 136.16 min followed by 94.41, 65.52, 20.58 min under ZrO2 NFMQL, pure oil MQL, and dry conditions. A substantial impact has been noticed on the cost savings under GO-NFMQL condition and cost saving have been reduced by 2.07%, 5.19%, and 5.48%, compared to ZrO2-NFMQL, MQL and dry environments respectively. Further, GO NFMQL environment performed better in both machinability and sustainability aspects than other environments as it gets the highest score of 11 in Pugh matrix sustainability assessment approach.

Temperature Analysis in Cubic Boron Nitrate Cutting Tool during Minimum Quantity Lubrication Turning with a Coconut-Oil-Based Nano-Cutting Fluid Using Computational Fluid Dynamics

The minimum quantity lubrication (MQL) approach is used for improving tool life at a low cost, and it is environmentally friendly. When compared to traditional flood cooling technology, the flow rate in MQL is thought to be 10,000 times lower. The workpiece’s surface smoothness is enhanced by continuous chip formation during turning, but because the tool is always in touch with the chip, a crater wear zone is formed on the rake face due to high friction and thermal stress. While adding nanoparticles to MQL enhances cutting performance, a high concentration of these nanoparticles causes burr adhesion and decreased chip evacuation capability due to the agglomeration of nanoparticles, which affects the surface finish of the workpiece. A novel “coconut-oil-based SiC–MWCNT nano-cutting fluid for a CBN insert cutting tool” is proposed in this approach to overcome these issues. Silicon carbide (SiC) and multi-walled carbon nanotubes (MWCNTs) are added to coconut oil with an appropriate volume fraction for better lubrication. The thermal properties of the proposed nano-cutting fluid are compared with those of some existing nano MQL cutting fluids, and it was found that the MQL cutting fluid under consideration exhibits an elevated thermal conductivity and convective heat transfer coefficient that efficiently reduce tool temperature and improve tool life. The comparative study between the Finite Element Simulation using computational fluid dynamics (CFD) predicted variation in tool temperature and the corresponding experimental values revealed a remarkable alignment with a marginal error ranging from 1.27% to 3.44%.

Evaluation of new nano-cutting fluids for the processing of carbon fiber-reinforced composite materials

Carbon fiber-reinforced composites (CFRP), known for its impressive specific strength and modulus, finds extensive applications in defense, aerospace, automotive, and various other industries. Nevertheless, the widespread application of dry cutting in machining Carbon Fiber Reinforced Polymer (CFRP) presents significant challenges, including dust pollution, fiber layer delamination, and uneven surface quality. These issues make the machining of CFRP a formidable task. In the present investigation, a novel nanohybrid cutting fluid was successfully prepared by adding molybdenum disulfide (MoS2)/silicon carbide (SiC) nanoparticles to a base-cutting fluid synthesize from ethanol, polyethylene glycol, and sodium dodecyl sulfate. Moreover, employing minimal lubrication techniques, the nano-cutting fluid was applied to the milling process of CFRP. The feasibility of applying the cutting fluid to CFRP machining was demonstrated through short beam shear tests. Horizontal comparative milling tests were executed on CFRP, varying operational parameters and cooling-lubrication scenarios. The cooling-lubrication mechanisms of the nanofluid were analyzed, providing further validation of the effectiveness of the cutting fluid in CFRP machining. The results suggest that the nanofluid has a negligible impact on the interlaminar shear strength of CFRP, with only a 3.85% reduction. In comparison to other cooling-lubrication conditions, milling CFRP with the novel nanofluid resulted in a reduction of milling forces by 4.78%–24.84%, a decrease in milling temperatures by 15.38%–69.37%, a lowering of surface roughness by 10.78%–35.93%, and a reduction in tool tip wear by 6.25%–53.81%. Observable phenomena such as fiber pull-out and fracture were significantly reduced.

Eksperimentalna procena biomaziva sa dodatkom nanočestica kalcijum karbonata (CaCO₃) iz otpada ljuske kapice kao tečnosti za sečenje korišćenjem minimalne količine podmazivanja (MKL) u CNC procesu glodanja

Nano-cutting fluid sprayed using the minimum quantity lubricant (MQL) method is one example of a green manufacturing process. Meanwhile, vegetable oil is an appropriate lubricating base oil as it offers very high lubricating performance and environmental friendliness. Further, CaCO₃ nanoparticles are popular for their capacity to improve lubrication properties and performance. However, the optimum impact of utilizing different types of vegetable oil remains inadequately investigated. Therefore, this study aims to analyze the effect of CaCO₃ nanoparticles on the performance of cutting fluid, specifically on the thermophysical, rheological, and tribological properties in the CNC milling process of AISI 1045 Steel material. The nano-cutting fluid was prepared using different vegetable oils (canola, corn, soybean) added with CaCO₃ nanoparticles with a mass concentration of 0.15%. The results showed that the thermophysical properties, including density and viscosity, were highest when using canola oil, and the addition of CaCO₃ to all samples did not significantly affect thermal conductivity. Meanwhile, for the rheological properties, we observed Newtonian for all cutting fluid samples. For tribological properties, canola, and corn oil were better for obtaining a minimum Ra value, while soyabean oil was more effective in reducing cutting temperature. Based on the results of tool wear calculations, each oil presents the best performance in reducing wear, especially with the addition of CaCO₃. For chip formation, on average, the samples produce irregular tooth morphology with C-type, comma, and elongation shapes. Meanwhile, the resulting chip color was dark purple, which changed to dark brown and light brown, then turned silvery white due to wear and tear on the different sides of the chisel.

ENHANCING MILLING PERFORMANCE OF 6061 ALUMINUM ALLOY WITH NANOCUTTING FLUID AND MQL

During the machining of aluminum alloys, the adhesion of chips to the tool affects the performance characteristics. Today, different cooling systems are used to eliminate these negativities. In this study, the effects of end milling using HSS and carbide cutting tools of 6061-T6 aluminum alloy on surface roughness, chip thickness ratio and tool wear were examined using different cooling techniques (dry, minimum quantity lubrication (MQL) and nanocutting fluid). Different cutting speeds (180, 200, 220 m/min) and different feed rates (0.05, 0.06, 0.07 mm/rev) were used in the experiments. According to experimental findings, tool wear and surface roughness decreased at low cutting speed and feed rate by using nanocutting fluid with carbide cutting tools. It has been observed that the chip thickness ratio increases with high cutting speeds using nanocutting fluid and decreases with dry machining and high feed rates. The best milling performance of the aluminum alloy was achieved in experiments using carbide cutting tools and nanocutting fluid.

WASPAS Based Multi Response Optimization in Hard Turning of AISI 52100 Steel under ZnO Nanofluid Assisted Dual Nozzle Pulse-MQL Environment

Hard turning is an emerging machining technology that evolved as a substitute for grinding in the production of precision parts from hardened steel. It offers advantages such as reduced cycle times, lower costs, and environmental benefits over grinding. Hard turning is stated to be difficult because of the high hardness of the workpiece material, which causes higher tool wear, cutting temperature, surface roughness, and cutting force. In this work, a dual-nozzle minimum quantity lubrication (MQL) system’s performance assessment of ZnO nano-cutting fluid in the hard turning of AISI 52100 bearing steel is examined. The objective is to evaluate the ZnO nano-cutting fluid’s impacts on flank wear, surface roughness, cutting temperature, cutting power consumption, and cutting noise. The tool flank wear was traced to be very low (0.027 mm to 0.095 mm) as per the hard turning concern. Additionally, the data acquired are statistically analyzed using main effects plots, interaction plots, and analysis of variance (ANOVA). Moreover, a novel Weighted Aggregated Sum Product Assessment (WASPAS) optimization tool was implemented to select the optimal combination of input parameters. The following optimal input variables were found: depth of cut = 0.3 mm, feed = 0.05 mm/rev, cutting speed = 210 m/min, and flow rate = 50 mL/hr.

Retracted: Influence of Nano-Cutting Fluid in New Cutting and Forming Processes on Heat Transfer Performance of Mechanical Engineering.

[This retracts the article DOI: 10.1155/2022/5603355.].

A green machining study to investigate the effect of nano-cutting fluid environments on the machinability of Ti6Al4V titanium alloy

This study primarily focuses on green machining, which refers to the environmentally friendly machining of parts without compromising the environment and human health. Green machining, an innovative approach in the manufacturing industry, aims to reduce the environmental impact and promote sustainable practices throughout the machining process. Green machining involves the utilization of methods such as machining, dry machining, high-performance cutting, hybrid machining, and high-speed cutting, along with environmentally friendly lubrication practices. The objective of this research is to investigate the effects of machining Ti6Al4V alloys, a widely used lightweight metal in the aerospace industry known for its challenging machinability. The study specifically examines cutting force, surface roughness, and tool wear under various cutting parameters and tribological conditions. The use of a new lubrication/cooling method was investigated in order to minimize the effects of traditional cutting fluids used in the machining of difficult materials, which may cause environmental and human health. This way, sustainable green production compatible with the environment has been realized today, where global warming and carbon emissions are rapidly increasing. In addition, it was observed that the factor determining the cutting force was the depth of cut and the feed rate was the most significant factor affecting the surface roughness.

Development and potential use of MWCNT suspended in vegetable oil as a cutting fluid in machining of Monel 400

The heat dissipation problem that arises when machining difficult to cut materials can be mitigated by using nano-cutting fluids, which have a much higher thermal conductivity value than the basic lubricants. Since the heat carrying capacity of the Minimum Quantity Lubrication (MQL) system is significantly lower than that of other coolants, a number of nano-additives are used to increase its cooling effectiveness. Therefore, this study firstly focuses on the assessment of nano-cutting fluids and theirsignificant efficacy in the machining operation of nickel-based alloys. Multi-walled carbon nanotube (MWCNT) suspended in vegetable oil is compared with distinct cooling environmental conditions namely, dry, MQL and cryogenic carbon dioxide (CO2). The novelty of this work is that the different volume fractions of 0.2 – 1 wt% of MWCNT were dispersed to study the contact angle, viscosity and thermal conductivity of the prepared molecular liquid and then, the potential of MWCNT suspended in vegetable oil is used to evaluate the outcomes of surface roughness (Ra), cutting temperature (CT) and tool wear (Vb) while machining Monel 400 alloy. The outcomes affirmed that employing nano MQL in machining operations resulted in a mean reduction of about 65% in the temperature evolved concerning no coolant condition. Additionally, the use of nanoparticles leads to an improved surface finish and abridged tool wear.

Effect of nanoparticles mixing-ratio of Al2O3-MWCNT hybrid nano-cutting fluid during MQL turning

ABSTRACT Recent research has focused on replacing traditional cutting fluids with nano-cutting fluids to enhance machining performance. Also, hybrid nano-cutting fluid composed of two or more types of nano-particles has gained popularity. The aim of this study is to investigate the effect of the mixing ratio of Al2O3 (Alumina) and MWCNT (multiwall carbon nanotubes) nanoparticles blended in vegetable oil during the turning of stainless steel SS-304 with minimum quantity lubrication (MQL) cutting conditions. Two hybrid nano-cutting fluids with 1.5% weight concentration have been prepared using Al2O3 and MWCNT nanoparticles in the ratio of 80:20 and 60:40. The performance of hybrid nano-cutting fluids containing nanoparticles of both Al2O3 and MWCNT simultaneously has been compared with mono nano-cutting fluid containing only Al2O3 nanoparticles. Results show that use of hybrid nano-cutting fluid containing 20% and 40% MWCNT resulted in improvement in surface roughness of workpiece by 13.6% and 6.86%, respectively, over mono nano-cutting fluid.

Effect of copper nano-cutting fluids in end milling of al 6061 and its influence on work piece morphology

Due to its exceptional mechanical qualities, aluminium 6061alloy is frequently utilised at automotive and aerospace industries. During the machining process, lubricating oil is typically supplied into the cutting zone to enhance machining performance, including tool life and workpiece surface quality. However, conventional coolants perform less effectiveat higher temperatures. The introduction of Copper Nano coolant at cutting interface could sustain greater temperatures. The surface finish of work piece is improved significantly as the Nano coolants at the tool-chip interface considerably reduces friction and thermal deformation. Utilizing the Minimum Quantity Lubrication (MQL) approach could reduce the amount of lubrication oil needed, reducing pollution. Cu Nano lubricants are made in concentrations of 0.2, 0.6, and 1.0% vol. in a water–oil base lubricant in a 20:1 ratio. The size, structure, and elemental content of the Cu nanoparticles are studied using EDX and FESEM. Cutting force, temperature, and surface quality are alsomeasured. It has been noted that the use of copper Nano coolants enhanced the workpiece's surface polish and greatly decreased the cutting forces and cutting temperatures. The development of thin layer over work piece is responsible for improved surface finish and reduced cutting forces and temperatures.

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.

INVESTIGATION OF CHIP MORPHOLOGY ON TURNING OF MONEL UNDER NANOGRAPHENE AND NANO CuO COOLANTS

This paper deals with experimental investigation on chip formation of machining of Monel K500 and its characteristics are studied. Two different nanocutting fluids namely nanoCuO and nanographenes are used for turning operation and the performance of the two cutting fluids is evaluated and the corresponding responses are recorded for the selection of better cutting fluid. This experiment is carried out with the help of SEM which picturizes the microstructure and surface distribution of the chips. The various output responses like chip thickness, chip compression ratio, and surface roughness are portrayed. The desirable effects on the properties of the machined material obtained by the variation of process parameters like cutting speed, cutting depth, and feed rate are analyzed. Results show that the thickness of chips (corresponding metal removal rate) is reduced considerably by 10–15% and the surface roughness is reduced by 20–30% when nanographene cutting fluids are used.

Performance of Al2O3/TiO2 Hybrid Nano-Cutting Fluid in MQL Turning Operation via RSM Approach

Cutting fluids can be used to cool workpieces at high cutting speeds and remove chips from cutting zones. The effectiveness of cutting fluids may be improved with the addition of hybrid nanoparticle dispersion. This study evaluates the effectiveness of an Al2O3-TiO2 hybrid as a cutting fluid in turning operations. The Al2O3-TiO2 hybrid nano-cutting fluid was prepared using a one-step method in computer numerical control (CNC) coolant with concentrations of up to 4%. Utilizing air-assisted nano-cutting fluids injected through a minimum quantity lubrication (MQL) setup, the effectiveness of turning cutting performance, cutting temperature (°C), average surface roughness (Ra), and tool wear (%) were evaluated. Then, the response surface method (RSM) was utilized as the design of experiment (DOE) to optimize the turning cutting performance parameters. The combination of 4% hybrid nano-cutting fluid concentration, 0.1 mm/rev feed rate, and 0.55 mm depth of cut yielded the lowest cutting temperature, surface roughness, and tool wear values of 25.3 °C, 0.480 µm, and 0.0104%, respectively. The 4% concentration of Al2O3/TiO2 hybrid nano-cutting fluid inclusion achieved the highest surface roughness reduction that led to better surface finish and the lowest tool-wear reduction led to longer tool life. Therefore, Al2O3/TiO2 hybrid nano-cutting fluids were strongly recommended in turning operations for CNC lathes.

Heat transfer mechanisms of nano-cutting fluids: a comparative performance analysis model

Heat transfer mechanisms of nano-cutting fluids: a comparative performance analysis model

Effectiveness of hybrid Al2O3-TiO2 nano cutting fluids application in CNC turning process

The purpose of this study is to evaluate the effectiveness of hybrid Al2O3-TiO2 nano-cutting fluid in the turning process application under the selected significant machining parameters consisting of nano concentration, depth of cut and feed rate. The preparation of aqueous hybrid Al2O3-TiO2 water-based nano-cutting fluids and their application as the cutting fluid in turning operations are undertaken. The Al2O3-TiO2 hybrid nano-cutting fluids were prepared through a one-step method; by dispersing nanoparticles of Al2O3 (average diameter 30 nm) and TiO2 (average diameter 30-50 nm) in CNC coolant based at four different volume concentrations (1%, 2%, 3%, 4%). The effectiveness of turning cutting performance, namely cutting temperature (°C), average surface roughness (Ra), and tool wear (%), were assessed via air-assisted nano cutting fluids impinged through MQL setup in turning of Aluminium Alloy AA7075. The response surface method (RSM) was employed in the design of the experiment (DOE). The lowest cutting temperature, surface roughness, and tool wear of 25.8°C, 0.494 µm, and 0.0107%, are obtained, respectively, when the combinations of hybrid nano cutting fluid concentration of 4%, feed rate value of 0.1 mm/rev, and 0.3 mm depth of cut is used. The result in this paper is based on the experimental study of Al2O3-TiO2 hybrid nano-cutting fluid using CNC turning operation. The process focuses on the finishing process by using a finishing insert. Further work using roughing process may be suggested to observe the better performance of this cutting process using nano-cutting fluid towards reducing the wear rate. The use of Al2O3-TiO2 hybrid nano-cutting fluid coupled with MQL in the CNC turning process is considered a new method. Machining soft and delicate materials such as Aluminium should consider using this combination technique since it lowers the cutting temperature and removes the chips, reducing the adhesive wear. The hybrid nano-cutting fluid can replace the conventional cutting fluid and will perform better if combined with the MQL cooling technique; this new method should be considered by major industry players that require a high-precision finished product such as the product that involves aircraft and aerospace applications.

Stability analysis of hybrid Al2O3-TiO2 nano-cutting fluids

This paper is to study the stability of the current combination of hybrid nano-cutting fluids due to the recent progress in the analysis of nano-cutting fluids, such as the assessment methods for the stability of nano-cutting fluids, have revealed that instability is a common problem associated with nano cutting fluids. Five samples of 0.001 vol% that are suitable to be tested at UV-Vis machine, Al2O3–TiO2 hybrid nano-cutting fluid was prepared using a one-step process with the help of a magnetic stirrer to stir for 30 minutes with different sonication time to determine the best or optimum sonication time for this hybrid nano-cutting fluid. Stability of nano-cutting fluids was analyses using UV–Vis spectrophotometer (0.001%, 0.0001%, 0.00001%), visual sedimentation (1%, 2%, 3%, 4%), TEM photograph capturing techniques (2%) and zeta potential analysis (0.001%, 0.00001%), that used different volume concentration that is suitable for each type of stability analysis. The stability analysis reveals that the best sonication time is 90 minutes, and the UV-vis spectrophotometer shows the stability of all samples is above 80% during a month compared to the initial value. Further, visual sedimentation shows good stability with minimum sedimentation and colour separation only. The zeta potential value also shows great stability with a value of 37.6 mV. It is found that the hybrid nano-cutting fluid is stable for more than a month when the nano is suspended in the base fluid of conventional coolant. The result in this paper is based on the experimental study of Al2O3-TiO2/CNC coolant base hybrid nano-cutting fluid for a month. However, to further validate the results presented in this paper, it is recommended to prolong the stability assessment time for six months for longer shelf life. The finding of this experimental study can be useful for high-precision product machining using similar CNC coolants, especially for aircraft and airspace applications for machining parts. No thorough stability assessment using all four types of stability analysis is done on Al2O3-TiO2/CNC Coolant base hybrid nano cutting fluid.