Nano-cutting Fluids Research Articles

Influence of Ag Nanoparticles for the Anti-wear and Extreme Pressure Properties of the Mineral Oil Based Nano-cutting Fluid

Influence of Ag Nanoparticles for the Anti-wear and Extreme Pressure Properties of the Mineral Oil Based Nano-cutting Fluid

Performance evaluation of using water and bio oil-based nanocutting fluids under minimum quantity lubrication with compressed cold air during milling operations of steel

The process machining of metal occurs increasing friction force and high temperature, consequently will affect the wear of tool and product quality. The cooling method contributes significantly to reduce heat, friction force and surface roughness of workpiece. The cooling method that used must develop to aim environmental machining process with minimum quantity lubrications (MQL) and dry cutting, but the dry cutting has limited performance because of low lubrications. The MQL using nanofluid base natural oil/water is major challenge in cooling method. In this study in order to aim high performance of cooling, the bionanofluid formed from high thermal conductivity of nanoparticles (50 nm) emulsifier by water and bio oil as base fluid in MQL process by injection of low temperature of air. To improve the cooling performance, it used cool air as injection pressure, designed by utilizing the evaporative process refrigerant flow with the counter flow direction. The experimental results show the lowest roughness was obtained from Titanium Dioxide TiO2 with palm oil-based fluid, followed Aluminum Oxide (Al2O3) based on coconut oil occurring, the last CuO in a water-based fluid. TiO2 most dispersing compared to others and correlates to cooling performance, it can be candidates for coolants for machining.

On machining of Ti-6Al-4V using multi-walled carbon nanotubes-based nano-fluid under minimum quantity lubrication

Titanium alloys are the primary candidates in several applications due to its promising characteristics, such as high strength to weight ratio, high yield strength, and high wear resistance. Despite its superior performance, some inherent properties, such as low thermal conductivity and high chemical reactivity lead to poor machinability and result in premature tool failure. In order to overcome the heat dissipation challenge during machining of titanium alloys, nano-cutting fluids are utilized as they offer higher observed thermal conductivity values compared to the base oil. The objective of this work is to investigate the effects of multi-walled-carbon nanotubes (MWCNTs) cutting fluid during cutting of Ti-6Al-4V. The investigations are carried out to study the induced surface quality under different cutting design variables including cutting speed, feed rate, and added nano-additive percentage (wt%). The novelty here lies on enhancing the MQL heat capacity using nanotubes-based fluid in order to improve Ti-6Al-4V machinability. Analysis of variance (ANOVA) has been implemented to study the effects of the studied design variables on the machining performance. It was found that 4 wt% MWCNTs nano-fluid decreases the surface roughness by 38% compared to the tests performed without nano-additives, while 2 wt% MWCNTs nano-fluids improve the surface quality by 50%.

Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718

Flood cooling is a typical cooling strategy used in industry to dissipate the high temperature generated during machining of Inconel 718. The use of flood coolant has risen environmental and health concerns which call for different alternatives. Minimum quaintly lubricant (MQL) has been successfully introduced as an acceptable coolant strategy; however, its potential to dissipate heat is much lower than the one achieved using flood coolant. MQL-nano-cutting fluid is one of the suggested techniques to further improve the performance of MQL particularly when machining difficult-to-cut materials. The main objective of this study is to investigate the effects of two types of nano-cutting fluids on tool performance and chip morphology during turning of Inconel 718. Multi-walled carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles have been utilized as nano-additives. The novelty here lies on enhancing the MQL heat capacity using different nano-additives-based fluids in order to improve Inconel 718 machinability. In this investigation, both nano-fluids showed better results compared to the tests performed without any nano-additives. Significant changes in modes of tool wear and improvement in the intensity of wear progression have been observed when using nano-fluids. Also, the collected chips have been analyzed to understand the effects of adding nano-additives on the chip morphology. Finally, it has been found that MWCNT nano-fluid has shown better performance than Al2O3 nano-fluid.

Nano-Cutting Fluids Technology: A Review

Proposing nano-cutting fluids contributes to facing the heat dissipation challenge during machining difficult-to-cut materials since they offer a highly observed thermal conductivity value in comparison with the base lubricants. Thus, several nano-additives are employed to improve the cooling and lubrication functions of the used base lubricants. The nano-additives have superior thermal and wettability characteristics which could significantly enhance the resultant nano-fluid properties. These properties include the ability to withstand the high generated temperature during machining difficult-to-cut materials. Also, they would enhance the nano-fluid tribological functions since the employed nano-additives work as spacers in the workpiece-tool interface area to reduce the induced friction during machining processes. Generally, nano-cutting fluids have shown promising effects on the cutting performance characteristics through different cutting operations such as turning, milling, and grinding. In the current work, a comprehensive review study about the nano-cutting fluid technology is presented. The study discussed different aspects related to the nano-cutting fluids and their applications such as, the preparation techniques of nano-fluids, characterization of nano-fluids stability, the thermal and rheological of the resultant nano-fluid, the nano-fluids effects on improving the cutting processes performance, and nano-fluids challenges.

Sustainability Assessment of Machining with Nano-Cutting Fluids

Proposing nano-cutting fluids contributes to facing the heat dissipation challenge during machining difficult-to-cut materials since they offer a highly observed thermal conductivity value in comparison with the base lubricants. Thus, several nano-additives are employed to improve the cooling efficiency of Minimum Quantity Lubrication (MQL) system since its heat capacity is much lower than the one achieved using flood coolant. MQL-nano-fluid technique offers two main advantages; (a) enhancing the machining process performance as the employed nano-additives improve the thermal and frictional behavior, and (b) accomplishing a more sustainable process as the MQL systems applies an optimal amount of oil compared to the flood coolant strategy. In this study, a previous general assessment algorithm has been implemented to find the optimal and sustainable process parameters levels during machining Inconel 718 with MQL-nano-fluids. Multi-walled-carbon-nano-tubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles have been utilized as nano-additives. The employed algorithm accommodates several machining responses, and sustainable metrics and indicators regardless of their criteria. It has been found that the assessment algorithm results were in agreement with the physical findings of the conducted experimental results.

Novel uses of alumina-MoS2 hybrid nanoparticle enriched cutting fluid in hard turning of AISI 304 steel

The present study investigates the effect of hybridization of two different nanofluids (alumina and molybdenum disulphide) in turning of AISI 304 stainless steel. The hybrid nanofluid was prepared by mixing alumina-based nanofluid with molybdenum disulphide (MoS2) nanoparticles in a fixed volumetric proportion of 90:10. The prepared base fluid (Alumina nanofluid) and hybrid nanofluid in various nanoparticle concentrations of 0.25, 0.75 and 1.25vol.% have been tested for their thermophysical properties at different temperatures. Furthermore, pin on disc test, and contact angle measurement of all the nanofluid samples was conducted to examine their tribology and wettability, respectively. The Response Surface Methodology (RSM) was used to design the experiment for turning. The regression models were developed and experimentally validated for all the three components of machining forces and surface roughness. The machining performances of hybrid nano-cutting fluid are compared with that of alumina-based nanofluid in terms of machining forces and surface roughness. The use of Al-MoS2 hybrid nano-cutting fluid has shown a significant reduction of 7.35%, 18.08%, 5.73%, and 2.38% respectively, in cutting force (Fz), feed force (Fx), thrust force (Fy) and surface roughness (Ra) compare to Al2O3 mixed nanofluid.

Emerging application of nanoparticle-enriched cutting fluid in metal removal processes: a review

In metal removal processes, the role of cooling and lubricating fluid is very crucial for improving the performance of machining. When metallic and non-metallic nanoparticles (less than 100 nm) are added to the base fluid, it is termed as a nanofluid. Due to excellent heat-carrying capacity, lubrication and rheological properties, nanofluids have gained immense importance for growing research activities. Researchers are also exploring synthesis and newer application of nanofluids. In the process, scientists are trying to develop new types of nano-cutting fluids, which are economic and eco-friendly. In this connection, investigations are also underway to find out possible mechanisms for improving cooling and lubricating properties of nanofluids. This paper presents a summary of published literature on the application of nano-enriched cutting fluid in various conventional metal removal processes, such as turning, milling, drilling and grinding. This paper also discusses the effects of different nano-enriched cutting fluids on various metal removal processes and factors influencing their process performance.

Performance evaluation of alumina-graphene hybrid nano-cutting fluid in hard turning

A hybrid nanofluid (NF) with better thermal and tribological properties has been developed in this investigation by mixing alumina-based nanofluid with graphene nanoplatelets (GnP) in the volumetric concentrations of 0.25, 0.75 and 1.25 vol %. It was noted that an increase of nanoparticle concentration enhances both, the thermal conductivity and viscosity, though the hybrid nanofluid has lower thermal conductivity compare to its constituents and the viscosity lies in between its constituents. The tribological test confirms that the wear decreases with the increase of nanoparticle concentration and the hybrid nanofluid generated least amount of wear. Hybrid nanofluid shows better wettability results as compared to alumina-based nanofluid as well as base fluid. The turning of AISI 304 steel under minimum quantity lubrication (MQL) technique clearly establishes that application of hybrid nanofluid performs better as compared to alumina nanoparticle mixed cutting fluid. The study reveals that blending of GnP with alumina enhances the performance of hybrid nanofluids. The application of hybrid nanofluid with MQL significantly reduces the surface roughness by 20.28% and cutting force, thrust force and feed force by 9.94%, 17.38% and 7.25%, respectively.

Investigation into Performance of SiO2 Nanoparticle Based Cutting Fluid in Machining Process

Nanofluid (NF) is a colloidal mixture of metallic or non-metallic particles of nanometre-size in a base fluid. In the present investigation, a nano-cutting fluid with better thermal and tribological properties has been developed by adding SiO2 nanoparticles into a vegetable oil-water emulsion in different volumetric concentrations. The prepared nanofluid is also characterized for its thermal conductivity and viscosity with various nanoparticle concentrations at different temperatures. Furthermore, its performance as a cutting fluid by using minimum quantity lubrication (MQL) technique has been examined in turning of AISI 1040 steel. The investigation results have also been compared with the results obtained by applying dry machining and wet/MQL machining techniques using conventional cutting fluid. The experiment clearly establishes that the performance of SiO2 nanofluid in terms of cutting force, surface roughness, tool flank wear and chip morphology is better compared to conventional cutting fluids, applied under wet/MQL machining and dry machining

Evaluation of Cutting Fluid With Nanoinclusions

Environmental and economic concerns on use of cutting fluids have led to use of minimum quantity cooling lubrication (MQCL) system, which uses minute quantity of cutting fluids, demanding a specialized fluid with improved properties. Investigation of any newly developed cutting fluid would be complete if it is evaluated with respect to its machinability, environmental and economic aspects. The present work investigates the viscosity, machinability characteristics, environmental effects, and economic aspects of a newly developed nanocutting fluid with varying concentrations of graphite nanoparticles applied at different flow rates to machining operation. It is found that the machinability improved with respect to conventional cutting fluid and this improvement increased with increase in concentration of nanoinclusions in the range 0.1–0.5 wt. % and also with increase in the flow rate. A regression model is developed for nanocutting fluids to estimate tool wear when used in the range 0.1–0.5 wt. % at flow rates 5 ml/min to 15 ml/min. The biodegradability is found to decrease with inclusion of nanoparticles due to the inorganic nature of selected nanoparticle. But its application as MQCL is ecofriendly as the nanocutting fluid is not disposed to the environment and graphite in it is neither toxic nor hazardous. Based on economic aspect, MQCL application with conventional cutting fluid and few cases of nanocutting fluids are found to be economic compared to flood lubrication. So a compromise has to be obtained between the economic and machinability aspects to choose an optimum cutting fluid.

Enhancement of surface finish using water-miscible nano-cutting fluid in ultra-precision turning

This paper presents an experimental study on the enhancement effect of the low viscosity cutting fluid enriched with nano-droplets (NDCF) in ultra-precision turning. Unlike the conventional method in which the enhancement is done by adding nano-metric particles, no suspension particles are mixed to produce the NDCF in this paper. Instead, the NDCFs are produced by atomisation of the cutting fluid that circulates in a closed-loop treatment device. The atomisation process is found to reduce the viscosity of the NDCF significantly by the formation of nano-droplets (NDs). The reduced viscosity of the NDCFs could be increased by diluting them with water. The bench tests on wetting properties reveal that the NDCF demonstrates two distinct properties: a very linear spreading rate and a relatively low contact angle. These two properties assist the NDCF in penetrating deeper into the tool–chip and tool–work interfaces and hence provides a better lubrication effect at these interfaces. In this paper, the ultra-precision cylindrical turning experiments reveal that the droplet size of the NDCF is a more important factor than viscosity on affecting the surface finish in ultra-precision machining.

Nano-Cutting Fluid for Enhancement of Metal Cutting Performance

Nano-cutting fluids are the mixtures of conventional cutting fluid and nanoparticles. Addition of the nanoparticles can alter wettability, lubricating properties, and convective heat transfer coefficient (cooling properties) of nano-cutting fluids. In the present work, nano-cutting fluid is made by adding 1% Al2O3 nanoparticles to conventional cutting fluid. The wettability characteristic of this nano-cutting fluid on a carbide tool tip is measured using the macroscopic contact angle method. Comparative study of tool wear, cutting force, workpiece surface roughness, and chip thickness among dry machining, machining with conventional cutting fluid as well as nano-cutting fluid has been undertaken. This study clearly reveals that the cutting force, workpiece surface roughness, tool wear, and chip thickness are reduced by the using nano-cutting fluid compared to dry machining and machining with conventional cutting fluid.