Nanofluid Minimum Quantity Lubrication Research Articles

Investigation of nanofluid minimum quantity lubrication on micro-grinding quality of SiCf/SiC ceramic matrix composites

Investigation of nanofluid minimum quantity lubrication on micro-grinding quality of SiCf/SiC ceramic matrix composites

Investigation of Surface Integrity of 304 Stainless Steel in Turning Process with Nanofluid Minimum-Quantity Lubrication Using h-BN Nanoparticles

This paper investigates the influence of the concentration and particle size of h-BN nanoparticles in a nanofluid on the surface integrity of 304 austenitic stainless steel during turning, focusing on the cutting force, friction coefficient, cutting temperature, surface roughness, surface residual stress, work hardening capacity, and 3D surface topography. The results show that, compared to dry cutting, the addition of 3 wt.% h-BN nanofluid can reduce the friction coefficient on the rake face by 38.9%, lower the cutting temperature by 43.5%, decrease the surface roughness by 53.8%, decrease the surface residual stress by 61.6%, and reduce the work hardening degree by 27.5%. Two-dimensional profiles and the 3D surface topography display a more balanced peak–valley distribution. Furthermore, by studying the effect of different h-BN particle sizes in nanofluids on the surface integrity of the machined workpiece, it was found that nanoscale particles have a greater tendency to penetrate the tool–chip interface than submicron particles. Moreover, the h-BN particles in the nanofluid play a “rolling effect” and “microsphere” effect, and the sesame oil will also form a lubricating oil film in the knife-chip contact area, thereby reducing the friction coefficient, reducing the cutting force, and improving the machining surface quality.

PERFORMANCE OPTIMIZATION OF BS970 MILD STEEL TURNING PARAMETERS UNDER SiC-MoS2 HYBRID NANOFLUID USING HYBRID DEEP BELIEF NETWORK BASED COOT OPTIMIZATION

In the modern world of competitive manufacturing, turning is a basic and important process that needs to be optimized for the fast-evolving industrial nature. It has its application in various fields involving numerous materials. This research study deals with modeling with optimization on the turning process parameters of turning E2-BS970 mild steel with cryogenically treated tungsten carbide tool under NFMQL having [Formula: see text] nanofluid. The parameters considered as the input factors are spindle speed and depth of cut along with feed rate and lubrication condition. The design of the experiment is done based on Box–Behnken design for 27 trials in the response surface method. The Deep Neural Network (DBN) and the Coot optimization algorithm are employed using MATLAB software for the prediction modeling. The prediction model developed by the DBN sigmoid function gave minimal error with prediction regression values of 0.99988 for MRR, 0.99516 for Cutting temperature, and 0.99545 for Tool life. The optimized result by CO shows a value of 188.89 rpm for spindle speed, 0.2318[Formula: see text]mm/rev for feed rate, Doc of 1.45[Formula: see text]mm, and 0.5015[Formula: see text]vol.% nanofluid MQL condition. The optimized values of MRR are 3.35[Formula: see text]mm3/min, [Formula: see text]C cutting temperature, and 1543.12[Formula: see text]s of tool life. The DBN model combined with the Coot algorithm shows minimal deviation compared to the experimental results validation and confirmatory analysis and is deemed suitable for efficient prediction.

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.

Multi-objective optimization for balancing surface roughness and material removal rate in milling hardened SKD11 alloy steel with SIO2 nanofluid MQL

In manufacturing practice, manufacturers always strive to achieve both quality and productivity targets simultaneously. In the first part, this study examines the relationship between input factors, including cutting speed, depth of cut, and feed rate, and the output response, which is surface roughness, when milling hardened SKD11 alloy steel under minimum coolant lubrication conditions using SiO2 nanofluid. The input parameters are divided into four levels to determine their influence on surface roughness and to find the optimal conditions for achieving the minimum surface roughness. The experimental design was conducted using an L16 array. A second-order regression model was developed to describe the relationship between the input variables and the output response. In the second part, multi-objective optimization was performed to simultaneously achieve the minimum surface roughness and the maximum material removal rate (MRR). The Response Surface Methodology (RSM) was employed in this study. The results indicated that to achieve the minimum surface roughness, machining should be performed at a cutting speed of 100 m/min, a cutting depth of 0.2 mm, and a feed rate of 0.01 mm/tooth. With these settings, the predicted surface roughness could reach 0.0451 µm. On the other hand, for the multi-objective optimization, to achieve the minimum surface roughness and the maximum MRR simultaneously, machining should be carried out at a cutting speed of 100 m/min, a cutting depth of 0.36 mm, and a feed rate of 0.0168 mm/tooth. With this cutting condition, the predicted surface roughness could reach 0.1069 µm, and the predicted MRR could reach 775.06 mm3/min

Optimizing SKD-61 steel machining for marine component manufacture: A grey-Taguchi study on nanofluid minimum quantity lubrication

SKD-61 steel finds extensive application in various sectors, including the marine industry where materials must withstand harsh aquatic conditions. In this study, we employ the Grey-Taguchi approach to optimize surface roughness (Ra), cutting force (Fc), and material removal rate (MRR) when hard-milling SKD-61 steel in pure minimum quantity lubrication (MQL) and nanofluid MQL environments, aligning with the demands of marine engineering. The orthogonal array method generates a set of experiments based on four input parameters: cutting speed, depth of cut, feed per tooth, and cutting condition, which are essential factors in marine component manufacturing. Our approach combines Grey relational analysis (GRA) with the Taguchi method to enhance multi-objective outcomes in machining. The results of this marine-focused study reveal that the lowest surface roughness, cutting force, and highest material removal rates are attained when the cutting conditions align with the principles of nanofluid MQL at a cutting velocity of 80 m/min, a depth of cut of 0.2 mm, and a feed per tooth of 0.01 mm/tooth. Keywords: hard milling, nanofluid MQL, optimization machining parameters; Grey relational analysis; Taguchi

Investigation of a green nanofluid added with graphene and Al2O3 nano-additives for grinding hard-to-cut materials

This study investigates Nanofluid Minimum Quantity Lubrication (NMQL) efficiency in grinding hard-to-cut materials by incorporating graphene and Al2O3 nano-additives into oleic acid-based nanofluids. Varied concentrations and ratios were examined, analyzing thermal conductivity, viscosity, and contact angle. NMQL assessment covered grinding force, specific grinding energy, temperature, surface quality, wear rate, and friction coefficient. Hybrid nanofluids displayed superior lubrication. At 1 wt% nano additives concentration, minimum specific grinding energies, friction coefficients, and friction test temperature increments were reduced by 73.92 %, 46.57 %, and 65.69 %, respectively in comparison with dry conditions. Optimal surface quality for ZrO2 and Ti-6Al-4V workpieces emerged at 2 wt% and 3 wt% nano additives concentrations, reducing surface roughness by 60.53 % and 48.66 %, respectively compared to dry cutting.

Parametric optimization to establish eco-friendly nanofluid minimum quantity lubrication (NMQL) practice for turning superalloy Inconel 718

Purpose The purpose of this paper, an experimental study, is to investigate the optimal machining parameters for turning of nickel-based superalloy Inconel 718 under eco-friendly nanofluid minimum quantity lubrication (NMQL) environment to minimize cutting tool flank wear (Vb) and machined surface roughness (Ra). Design/methodology/approach The central composite rotatable design approach under response surface methodology (RSM) is adopted to prepare a design of experiments plan for conducting turning experiments. Findings The optimum value of input turning parameters: cutting speed (A), feed rate (B) and depth of cut (C) is found as 79.88 m/min, 0.1 mm/rev and 0.2 mm, respectively, with optimal output response parameters: Vb = 138.633 µm and Ra = 0.462 µm at the desirability level of 0.766. Feed rate: B and cutting speed: A2 are the leading model variables affecting Vb, with a percentage contribution rate of 12.06% and 43.69%, respectively, while cutting speed: A and feed rate: B are the significant factors for Ra, having a percentage contribution of 38.25% and 18.03%, respectively. Results of validation experiments confirm that the error between RSM predicted and experimental observed values for Vb and Ra is 3.28% and 3.75%, respectively, which is less than 5%, thus validating that the formed RSM models have a high degree of conformity with the obtained experimental results. Practical implications The outcomes of this research can be used as a reference machining database for various metal cutting industries to establish eco-friendly NMQL practices during the turning of superalloy Inconel 718 to enhance cutting tool performance and machined surface integrity. Originality/value No study has been communicated till now on the turning of Inconel 718 under NMQL conditions using olive oil blended with multi-walled carbon nanotubes-based nanofluid. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2023-0317/

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.

The Effect of MoS2 and MWCNTs Nanomicro Lubrication on the Process of 7050 Aluminum Alloy

Nanofluid Minimum Quantity Lubrication (NMQL) is a resource-saving, environmentally friendly, and efficient green processing technology. Therefore, this study employs Minimum Quantity Lubrication (MQL) technology to conduct milling operations on aerospace 7050 aluminum alloy using soybean oil infused with varying concentrations of MoS2 and MWCNTs nanoparticles. By measuring cutting forces, cutting temperatures, and surface roughness under three different lubrication conditions (dry machining, Minimum Quantity Lubrication, and nanofluid minimum quantity lubrication), the optimal lubricating oil with the best lubrication performance is selected. Under the conditions of hybrid nanofluid minimum quantity lubrication (NMQL), as compared to dry machining and Minimum Quantity Lubrication (MQL) processing, surface roughness was reduced by 48% and 36% respectively, cutting forces were decreased by 35% and 29% respectively, and cutting temperatures were lowered by 44% and 40%, respectively. Under the conditions of hybrid nanofluid minimum quantity lubrication, the optimal parameter combination is cutting speed (Vc) of 199.93 m/min, feed rate (f) of 0.18 mm, cutting depth (ap) of 0.49 mm, and nanofluid mass fraction (wt) of 0.51%. The hybrid nanofluid can significantly enhance heat exchange capacity and lubrication performance, thereby improving machining characteristics.

Al<sub>2</sub>O<sub>3</sub> Nanofluids: An Experimental Study for MQL Grinding

In the course of grinding, conventional grinding fluid is frequently utilised, which leads to excessive consumption and negative environmental effects. MQL, or minimum quantity lubrication, is a possible replacement for traditional dry and fluid coolant application. It is well known that the MQL grinding process's effectiveness depends on the lubricating and cooling capabilities of fluid. A water-based Al2O3 nanofluid was used in this work to grind materials due to its outstanding convective heat transfer and thermal conductivity qualities. Hardened steel's grinding properties are examined and contrasted with those of MQL grinding done in wet, dry, and pure water. Al2O3 nanofluid MQL grinding using water dramatically lower the grinding temperatures, minimise grinding forces, and enhance the ground surface finish.

Machining performance and sustainability analysis of Al2O3-CuO hybrid nanofluid MQL application for milling of Ti-6Al-4V

Machining of Ti-6Al-4V presents challenges due to its low thermal conductivity, and conventional cutting fluids (CCF) are inadequate in providing a productive and sustainable solution. This study aims to achieve more sustainable and productive machining of Ti-6Al-4V by utilizing Al2O3 and CuO-added Nanofluid Minimum Quantity Lubrication (NMQL) individually and in hybrid form with different concentrations. A comparison is made with pure-MQL, CCF and dry conditions. The study consists of three stages. In the first stage, the physical properties of the coolants, like contact angle and surface tension, are investigated. The second stage involves slot milling operations, and various outputs including cutting forces, surface roughness, surface topography, surface finish, and subsurface microhardness are analyzed. In the last stage, a sustainability analysis is conducted based on the Pugh Matrix Approach. The results indicate that Al2O3-NMQL exhibits lower contact angles and surface tensions compared to other conditions. Furthermore, HNMQL applications result in lower cutting forces (up to 46.5%), surface roughness (up to 61.2%), and microhardness (up to 6.6%), while yielding better surface finish and topography compared to CCF. The sustainability analysis demonstrates that HNMQL application is the most suitable option for achieving sustainable machining of Ti-6Al-4V.

An experimental investigation on machining-induced surface/subsurface characteristics of nickel based Inc-718 alloy: A novel hybrid approach in milling process

Nickel-based superalloy Inc-718 has become an indispensable alloy in critical sectors, especially in the aerospace industry, thanks to its unique characteristics. However, some properties of the alloy (especially low thermal conductivity and hot hardness) cause difficulties in its machinability. For this reason, comprehensive studies to improve the machinability of Inc-718 alloy by considering the microstructural properties are guiding. In this context, the present study uses various methods to increase the machinability efficiency of Inc-718, while also investigating their effect on microstructural properties. Firstly, the effect of the pre-heating process (hot), pure-MQL (PMQL), nanofluid-MQL (NMQL), and hybrid methods (hot+PMQL and hot-NMQL) on the surface roughness, cutting forces, tool wear, vibration, and temperature was investigated while milling Inc-718 surfaces. Then the utilization of Electron Backscatter Diffraction (EBSD) facilitated a comprehensive examination of microstructural behavior, with a specific focus on Euler-colored maps and phase distribution maps, providing valuable insights into the material's behavior under distinct milling conditions. As a result, hot+PMQL, hot+SiC-NMQL, and hot+Al2O3-NMQL provided an important contribution to the improvement of machinability characteristics. Also, it was seen that in EBSD analysis, a limited area is affected by heat in the hot machining environment. The crystal orientations of the pre-heated and hybrid machined Inc-718 alloy are highly similar to that of the dry-machined alloy. This similarity indicates that the removal of the heated layer from the workpiece during the milling process contributes to the preservation of the microstructure.

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.

Surfactant free enhancement to thermophysical and tribological performance of bio-degradable lubricant with nano-friction modifier for sustainable end milling of Incoloy 925

An efficient method of lubrication and cooling for green machining is nanofluid minimum quantity lubrication (NMQL). Compared to other vegetable-based oils, coconut oil has the highest viscosity index, lubricity, and oxidative characteristics, making it a popular trending lubricant for decreasing friction. However, its performance at higher temperatures degrades owing to higher saponification value. In order to improve its performance, the solid nano-friction modifier (hBN) is dispersed in it, and the colloid is called a nanofluid. UV–Vis–NIR spectrophotometer, HR-TEM, and FTIR spectroscopy characterize nanofluid. The stability of nanofluid at 0.3 vol% of hBN has been observed to be the highest compared to other volume fractions. Compared to coconut oil, prepared nanofluid is superior in terms of increased thermal conductivity, thermal stability, and viscosity for all the tested temperature ranges. Nanofluid shows increased viscosity index (VI) by 20%, reduced contact angle by 45%, and lower coefficient of friction (COF) by 32% compared to coconut oil. Further performance of this modified biodegradable nanofluid under Minimum quantity lubrication (MQL) on end milling of Incoloy 925 has been studied. In order to compare the machining performance under different cutting environments, cutting temperature, cutting force, specific cutting energy, power consumption, carbon emission, chip morphology, surface topology/topography, and tool wear were evaluated. Finally, sustainability assessments for different cutting environments have been performed. Biodegradable oil-based NMQL-assisted machining has performed better than dry and MQL-assisted machining.

Atomization mechanism and machinability evaluation with electrically charged nanolubricant grinding of GH4169

Nanofluid minimum quantity lubrication (NMQL), which offers excellent economic and environmental benefits, has the greatest potential to replace traditional metal grinding with fluids. However, insufficient infiltration performance, poor atomization properties, and inferior controllability are found in pneumatic atomization minimum quantity lubrication (MQL), hindering the improvement of grinding performance. Electrostatic atomization MQL (EMQL) is expected to address the coexistence of grindability and sustainability through electrical charge empowerment. Nevertheless, studies addressing the effects and mechanisms of electrically charged nanolubricants in the grinding of nickel-based superalloys remain scarce. In this study, the atomization characteristics of EMQL are experimentally investigated, and results show that the droplet volume average diameter and diameter Rosin–Rammler distribution span of EMQL decreased by 7.1 % and 40.3 %, respectively, in comparison with those of MQL. Then, a series of grinding experiments on GH4169 with different cooling conditions are conducted. Results show that compared with those for MQL grinding, the coefficients of friction for EMQL and NMQL grinding decreased by 9.35 % and 15.62 %, the specific grinding energies decreased by 16.71 % and 29.06 %, and the values of surface roughness Sa decreased by 3.04 % and 14.33 %, respectively. The optimal combination of atomization method and medium for grinding GH4169 is EMQL and nanolubricant. Sa showed a 16.12 % decrease for the surface machined via the optimal combination compared with the surface machined via flooding. Last, to support the interpretation of the grinding outcomes, the antifriction mechanisms of electrically charged nanolubricants are analyzed in combination with the wetting, infiltration, and film-formation capabilities of droplets. The findings of this work are expected to provide experimental references for the surface integrity improvement of the nickel-based superalloy grinding process.

Influence of nanoparticle concentration in nanofluid MQL on cutting forces, tool wear, chip morphology when milling of Inconel 718

Influence of nanoparticle concentration in nanofluid MQL on cutting forces, tool wear, chip morphology when milling of Inconel 718

Nanofluids Minimal Quantity Lubrication Machining: From Mechanisms to Application

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

Assessment of Lubrication Property and Machining Performance of Nanofluid Composite Electrostatic Spraying (NCES) Using Different Types of Vegetable Oils as Base Fluids of External Fluid

The current study of minimum quantity lubrication (MQL) concentrates on its performance improvement. By contrast with nanofluid MQL and electrostatic atomization (EA), the proposed nanofluid composite electrostatic spraying (NCES) can enhance the performance of MQL more comprehensively. However, it is largely influenced by the base fluid of external fluid. In this paper, the lubrication property and machining performance of NCES with different types of vegetable oils (castor, palm, soybean, rapeseed, and LB2000 oil) as the base fluids of external fluid were compared and evaluated by friction and milling tests under different flow ratios of external and internal fluids. The spraying current and electrowetting angle were tested to analyze the influence of vegetable oil type as the base fluid of external fluid on NCES performances. The friction test results show that relative to NCES with other vegetable oils as the base fluids of external fluid, NCES with LB2000 as the base fluid of external fluid reduced the friction coefficient and wear loss by 9.4%-27.7% and 7.6%-26.5%, respectively. The milling test results display that the milling force and milling temperature for NCES with LB2000 as the base fluid of external fluid were 1.4%-13.2% and 3.6%-11.2% lower than those for NCES with other vegetable oils as the base fluids of external fluid, respectively. When LB2000/multi-walled carbon nanotube (MWCNT) water-based nanofluid was used as the external/internal fluid and the flow ratio of external and internal fluids was 2:1, NCES showed the best milling performance. This study provides theoretical and technical support for the selection of the base fluid of NCES external fluid.

Wear suppression and interface properties of diamond tool in micro-milling of TC4 alloy under graphene nanofluid MQL environment

The sustainable micro-milling process of TC4 alloy has garnered significant attention in aerospace engineering. However, the poor machinability of TC4 alloy results in particularly severe tool wear. Tool wear directly affects the machining quality of the parts, and traditional cutting fluids of suppressing tool wear indirectly increase production costs and pollute the environment. Therefore, to suppress the negative effects caused by tool wear, this paper proposes the application of water-based graphene nanofluid in the micro-milling of TC4 alloy in diamond tools. Firstly, micro-milling experiments and molecular dynamics simulations were conducted in different environments, including dry and water-based graphene nanofluid environments. Finally, tool surface wear morphology, milling forces, surface elements and structural phase changes were compared in detail. The results show that tool wear, including adhesive wear, abrasive wear, and edge chipping, was suppressed by graphene nanofluids compared to dry conditions, thereby increasing tool life. The graphene nanofluid improved the contact state between the tool and workpiece interface, reducing the milling forces. In addition, molecular dynamics indicates that the catalytic effect of the transition elements in the workpiece on the diamond tool was also weakened, and the carbon atoms of graphene were used as a sacrificial source to balance the catalytic effect. Graphitization and diffuse wear of the diamond were suppressed. More importantly, the water-based graphene nanofluid not only improves the wear resistance of the tool, but the LCA results show its potential for sustainability. Consequently, it holds promise for advancing the sustainable processing of challenging materials.