Machining Properties Research Articles

An experimental examination of the dry drilling machinability features of cellular glass‐filled new‐generation metallic composite foams

AbstractOn the way to the real industrial applications of the metal matrix composite foams, the machining issue is highly critical in terms of dimensional accuracy, surface quality, and design diversity. Therefore, especially for lightweight automotive and aerospace components, the drilling machinability properties of cellular glass‐added aluminum composite foams were examined in this paper, and this is the first initiative in the literature specific to millimeter‐scale glass and aluminum‐zinc matrix combination. To comprehend the drilling properties, the outputs of thrust force, cylindricity, material removal rate, specific cutting coefficient, circularity error, damage factor, surface roughness, and chip formation were measured elaboratively. The results showed that cylindricity and damage factor of foams elevated with the increased feed rates (from 0.05 mm×rev−1 to 0.2 mm×rev−1) and cutting speeds (from 25 m×min−1 to 100 m×min−1). Maximum thrust force value reached up to 150 N for 0.2 mm×rev−1 feed and 25 m×min−1 cutting speed. Besides, specific cutting coefficient values ranged between 360 MPa and 114 MPa. The highest surface roughness of 58.3 μm was obtained with the lowest cutting speed of 25 m×min−1, and the long/continuous chip structure converted into a separate/short structure based on rising feed and cutting speeds.

The Effect of Mn and Ti Ratio on Microstructure and Mechanical and Machinability Properties of 316 L Stainless Steel Used in Biomedical Applications

In this study, titanium (Ti) and manganese (Mn) element powders in determined amounts (0.35–0.75 and 1.5 wt %) were added into the 316 L stainless steel matrix by means of powder metallurgy (PM) technology, either individually or in pairs, and the desired composition was obtained as a powder mixture. The powders used in the study were cold-pressed tensile sample molds prepared in ASTM E8M standards, unidirectionally cold-pressed under 750 MPa compression pressure and formed into blocks. After pressing, the raw strength samples were sintered in an atmosphere-controlled tube furnace at 1250 °C for two hours in an argon atmosphere. The microstructure and mechanical properties of the produced PM steels were characterized using an optical microscope, SEM, EDS, tensile test, and hardness test. The results showed that the stainless steel samples with 0.35 (Ti and Mn) added to 316 L stainless steel had the highest yield strength, tensile strengths, and hardness strengths. However, with the addition of 0.75–1.5 Ti, 0.75–1.5 Mn and 0.75–1.5 (Ti and Mn) to 316 L stainless steel, a decrease was observed in the mechanical properties. Moreover, the stainless steel sample with 0.35 (Ti and Mn) added to 316 L stainless steel is better than other samples in terms of surface quality.

Strontium-Substituted Nanohydroxyapatite-Incorporated Poly(lactic acid) Composites for Orthopedic Applications: Bioactive, Machinable, and High-Strength Properties.

Traditional metal-alloy bone fixation devices provide structural support for bone repair but have limitations in actively promoting bone healing and often require additional surgeries for implant removal. In this study, we focused on addressing these challenges by fabricating biodegradable composites using poly(lactic acid) (PLA) and strontium-substituted nanohydroxyapatite (SrHAP) via melt compounding and injection molding. Various percentages of SrHAP (5, 10, 20, and 30% w/w) were incorporated into the PLA matrix. We systematically investigated the structural, morphological, thermal, mechanical, rheological, and dynamic mechanical properties of the prepared composites. Notably, the tensile modulus, a critical parameter for orthopedic implants, significantly improved from 2.77 GPa in pristine PLA to 3.73 GPa in the composite containing 10% w/w SrHAP. The incorporation of SrHAP (10% w/w) into the PLA matrix led to an increased storage modulus, indicating a uniform dispersion of SrHAP within the PLA and good compatibility between the polymer and nanoparticles. Moreover, we successfully fabricated screws using PLA composites with 10% (w/w) SrHAP, demonstrating their formability at room temperature and radiopacity when observed under X-ray microtomography (micro-CT). Furthermore, the water contact angle decreased from 93 ± 2° for pristine PLA to 75 ± 3° for the composite containing SrHAP, indicating better surface wettability. To assess the biological behavior of the composites, we conducted in vitro cell-material tests, which confirmed their osteoconductive and osteoinductive properties. These findings highlight the potential of our developed PLA/SrHAP10 (10% w/w) composites as machinable implant materials for orthopedic applications. In conclusion, our study presents the fabrication and comprehensive characterization of biodegradable composites comprising PLA and strontium-substituted nanohydroxyapatite (SrHAP). These composites exhibit improved mechanical properties, formability, and radiopacity while also demonstrating desirable biological behavior. Our results suggest that these PLA/SrHAP10 composites hold promise as machinable implant materials for orthopedic applications.

Use of sustainable cooling/lubrication strategies in improving the tribological and machining characteristics of gun metal

The term “sustainable manufacturing” refers to both the production of sustainable products as well as the production of all products in a way that is environmentally friendly, energy efficient, and safe for workers, communities, and customers. In the context of sustainable machining, the application of non-polluting cutting fluids plays an important role in improving the machining properties. However, the machining of gun metal is difficult because of generation of friction and cutting temperature at main cutting zone. Hence, it’s very difficult to obtain the product made from gun metal at specific size and desired tolerances. A primary goal of this paper is to establish an accurate method for measuring the machining responses of gun metal with the aid of sustainable cooling strategies. The machining has been carried out using the TiAlN coated tungsten carbide inserts and the machining performance in terms of temperature, surface quality, tool wear, chip condition and power consumed is measured under distinct speed-feed and cutting regimes. The cutting parameters selected were the speed of 75 and 115 m/min and the feed rate of 0.05–0.15 mm/rev. The utilization of cryogenic carbon dioxide (cryo) results in a maximum temperature reduction, which in turn leads to an improvement in the surface quality. In comparison to other cutting settings, the SEM pictures of chip indicate a relatively low level of serration; nonetheless, there is not a significant difference between MQL and flood circumstances. Moreover, cryo-CO2 consumed less power to machine the work material.

Experimental Investigation of Ultrasonic Vibration-Assisted Grinding of HVOF-Sprayed WC-10Co-4Cr Coating

WC-10Co-4Cr coating is highly valued for its corrosion resistance and wear resistance when applied using the high-velocity oxy-fuel (HVOF) spraying method. However, conventional grinding (CG) of this coating presents challenges, including substantial grinding forces and elevated surface temperatures. To address these concerns, our study proposed the utilization of ultrasonic vibration-assisted grinding (UVAG) as a means to enhance the machining properties of HVOF-sprayed WC-10Co-4Cr coatings. Comparative experiments were conducted to analyze the impacts of various factors on the grinding forces and surface roughness in UVAG and CG processes. Additionally, the topography of the ground surfaces was examined to gain insights into the material removal mechanism in UVAG. The experimental outcomes reveal significant reductions in tangential and normal grinding forces, amounting to 15.47% and 22.23%, respectively, in UVAG when compared with CG. Furthermore, UVAG led to a roughly 29.14% decrease in ground surface roughness compared with CG. Microscopic analysis of the ground surfaces using scanning electron microscopy (SEM) indicated that ductile removal was the predominant material removal mode in UVAG. Overall, UVAG was found to be effective in diminishing grinding forces, improving ground surface roughness, and enhancing surface integrity when contrasted with CG. These findings introduce a novel approach for processing WC-10Co-4Cr coatings.

Persistent Voltage Control of a Wind Turbine-Driven Isolated Multiphase Induction Machine

The growing concern about the energy crisis and environmental protection has caused a growing interest in wind power generation systems. Researchers and engineers urgently need to create new multiphase induction machines for the production of wind energy, since they are essential parts of wind turbines. This study offers control and stability analysis of a multiphase induction machine based on the entropy stability requirements for its linearized model. The generated model was used to assess the on-load properties of the multiphase induction machine and calculate its steady-state parameters under each operating circumstance. According to the analysis, the eigenvalues depend on the machine parameters, with the excitation capacitance and speed variation being the most important. Stabilization of the multiphase induction machine is the main focus of the singular values, which vary according to its variables. The simulated results include an examination of a multiphase induction machine steady state for voltage build-up at various types of load.

Cyclomap: A new phase-cycle analysis to study the kinematics of gears and bearings

The object of this paper is to propose a new phase-cycle analysis for gear and bearing diagnostics of rotating machinery which synthesises the theory of angle-time cyclostationary (AT-CS). The motivation for this research came from bearing diagnostics which is confronted by the inevitable smearing phenomenon due to bearing slip. The bearing signal under non-stationary conditions is neither jointly second-order cyclostationary (CS2) nor pseudo-cyclostationary (pseudo-CS) and, hence, most CS2 tools are subjected to loss of diagnostics information. The proposed phase-cycle analysis is believed to propound the study of the kinematics of gears and bearings, and it will significantly modify the prevailing historical interpretation of the bearing slip. In this paper, the phase-cycle analysis which is based on the theory of AT-CS is named the “cyclomap” because it can provide much more information about the kinematics of cyclostationary and cyclo-non-stationary signals. The cyclomap shows some interesting features in delineating the energy distribution of the kinematical properties of machines at an angular period of interest. In order to further study the properties of the cyclomap, it is systematically compared to the well-known order-frequency cyclic modulation coherence in diagnosing the CS2, pseudo-CS, and second-order cyclo-non-stationary signals of the experimental datasets.

Stability of oscillator Ising machines: Not all solutions are created equal

Nonlinear dynamical systems such as coupled oscillators are being actively investigated as Ising machines for solving computationally hard problems in combinatorial optimization. Prior works have established the equivalence between the global minima of the cost function describing the coupled oscillator system and the ground state of the Ising Hamiltonian. However, the properties of the oscillator Ising machine (OIM) from a nonlinear control viewpoint, such as the stability of the OIM solutions, remain unexplored. Therefore, in this work, using nonlinear control-theoretic analysis, we (i) identify the conditions required to ensure the functionality of the coupled oscillators as an Ising machine, (ii) show that all globally optimal phase configurations may not always be stable, resulting in some configurations being more favored over others and, thus, creating a biased OIM, and (iii) elucidate the impact of the stability of locally optimal phase configurations on the quality of the solution computed by the system. Our work, fostered through the unique convergence between nonlinear control theory and analog systems for computing, provides a new toolbox for the design and implementation of dynamical system-based computing platforms.

Analysis of Torque Capability for Permanent Magnet Machines With Magnetic Gear Effect

Permanent magnet (PM) machines have been widely applied in industrial applications due to the advantages of high torque density, high reliability, and high efficiency. In this paper, the magnetic gear effect (MGE) in PM machines is investigated in depth. A comprehensive derivation of the torque-generating process is carried out and a quantitative analysis of the air-gap harmonics contributing to average torque under different configurational freedoms is studied. The improvement of torque capability for the PM machines with MGE is discussed. The electromagnetic properties of typical PM machines with MGE are analyzed based on the magnetic circuit analytical model, and the effectiveness of theoretical analysis is verified by finite element analysis and experimental prototype. It is shown that the PM machines with an independent modulation unit possess the characteristics of high torque density and large PM utilization rate. And the PM machines with tooth-pole modulation unit have strong overload capability.

Influence of post-processing and build orientation on the micro-machinability and chip formation during micro-drilling of L-PBF AlSi10Mg

The requirement of micro holes or features on the additively manufactured (AM) components attract machinability investigations on Laser Powder Bed Fused (L-PBF) components, and directional anisotropy is one of the critical problems with parts made using L-PBF. As a result, the current study compares the machinability properties during the micro-drilling of several samples, including cast and L-PBF-produced AlSi10Mg. Moreover, the impact of T6 solution heat treatment and build orientation on microstructure, thrust force, cutting torque, surface roughness, and cutting temperature is analyzed. It was found that at a feed of 8 µm/rev and 5000 rpm, the force requirement perpendicular to the build direction (PPBD) was 23.11 % higher than parallel to the build plane direction (PBD). The force required is reduced after heat treatment because of the reduction in hardness. Similarly, a difference of 31.36 % in cutting torque requirement was observed, which increased to 46.82 % after heat treatment. At the same time, the difference in chip temperature in the as-built AlSi10Mg was less between PPBD and PBD. It was also observed that there is a reduction in the chip temperature with feed rate. The chip formation was further studied using a high-speed camera, and four stages of chip formation were identified. From the SEM analysis of the chips, microchips of different lengths and morphology can be identified, which are dissimilar to one another.

Thermodynamic and Microstructural Analysis of Lead-Free Machining Aluminium Alloys with Indium and Bismuth Additions.

The present study comprises an investigation involving thermodynamic analysis, microstructural characterisation, and a comparative examination of the solidification sequence in two different aluminium alloys: EN AW 6026 and EN AW 1370. These alloys were modified through the addition of pure indium and a master alloy consisting of indium and bismuth. The aim of this experiment was to evaluate the potential suitability of indium, either alone or in combination with bismuth, as a substitute for toxic lead in free-machining aluminium alloys. Thermodynamic analysis was carried out using Thermo-Calc TCAL-6 software, supplemented by differential scanning calorimetry (DSC) experiments. The microstructure of these modified alloys was characterised using SEM-EDS analysis. The results provide valuable insights into the formation of different phases and eutectics within the alloys studied. The results represent an important contribution to the development of innovative, lead-free aluminium alloys suitable for machining processes, especially for use in automatic CNC cutting machines. One of the most important findings of this research is the promising suitability of indium as a viable alternative to lead. This potential stems from indium's ability to avoid interactions with other alloying elements and its tendency to solidify as homogeneously distributed particles with a low melting point. In contrast, the addition of bismuth does not improve the machinability of magnesium-containing aluminium alloys. This is primarily due to their interaction, which leads to the formation of the Mg3Bi2 phase, which solidifies as a eutectic with a high melting point. Consequently, the presence of bismuth appears to have a detrimental effect on the machining properties of the alloy when magnesium is present in the composition.

Influence of the Friction Stir Process on the Corrosion Resistance, Machining, and Mechanical Properties of Al6101-SiC Composite

In this study, friction stir processing (FSP) was used to create new surface properties of the Al 6101-SiC composite, and different types of friction stir process tools are used like cylindrical with thread and conical with thread. The SEM and EDAX analyses made it evident that texture appeared in FSPed Al6101 both with and without SiC. Due to the refined grain structure and the inclusion of SiC in the composite, both FSPed samples’ hardness and tensile strength were found to be higher than those of the base alloy. In contrast to FSPed and base material, the composite had a lower percentage of elongation. Drilling experiments led to machining research that showed FSPed Al6101 to have larger cutting forces than the base and composite materials. These findings revealed that SiC served as reinforcement in the material, increasing hardness and cutting forces during drilling. Electrochemical tests on the corrosion behavior showed that the composite had less corrosion resistance than the FSPed alloy but had slightly better corrosion resistance than the base material. Al6101-SiC composites were found to have superior mechanical characteristics and greater machinability. However, when creating an Al6101-SiC composite via FSP, it is crucial to consider corrosion resistance degradation.

State‐of‐the‐Art in the Control of Sulfides in Steels

Sulfides like MnS are common phases in resulfurized free‐cutting steels, and are required to be controlled during the hot working process due to its influence on machinability, mechanical, and physical properties of final products. This article extensively reviews published researches on sulfides in resulfurized free‐cutting steels. The formation mechanism and modification of MnS during steelmaking, casting, and heat treatment are discussed based on a number of relevant studies. Measures to control the morphology and number of sulfides are supplied, which are beneficial for the production of resulfurized free‐cutting steels with high quality. Thermodynamic calculation proves to be an effective method to predict and control sulfides.

Decorated bacteria-cellulose ultrasonic metasurface

Cellulose, as a component of green plants, becomes attractive for fabricating biocompatible flexible functional devices but is plagued by hydrophilic properties, which make it easily break down in water by poor mechanical stability. Here we report a class of SiO2-nanoparticle-decorated bacteria-cellulose meta-skin with superior stability in water, excellent machining property, ultrathin thickness, and active bacteria-repairing capacity. We further develop functional ultrasonic metasurfaces based on meta-skin paper-cutting that can generate intricate patterns of ~10 μm precision. Benefited from the perfect ultrasound insulation of surface Cassie-Baxter states, we utilize meta-skin paper-cutting to design and fabricate ultrathin (~20 μm) and super-light (<20 mg) chip-scale devices, such as nonlocal holographic meta-lens and the 3D imaging meta-lens, realizing complicated acoustic holograms and high-resolution 3D ultrasound imaging in far fields. The decorated bacteria-cellulose ultrasonic metasurface opens the way for exploiting flexible and biologically degradable metamaterial devices with functionality customization and key applications in advanced biomedical engineering technologies.

Investigation on Mechanical and Machinability Properties of Aluminium Metal Matrix Composite Reinforced with Titanium Oxide (TiO2) and Graphite (Gr) Particles

This research paper deals with the preparation process and testing of metal matrix composites comprising Aluminium alloy (Al 6061) as the base metal and Titanium oxide (TiO2) and Graphite (Gr) as reinforcements. Due to their high specific strength, superior malleability, lightweight, stiffness and excellent resistance to corrosion, oxidation and wear, the aluminium metal matrix composites are preferred in the automobile and industrial sectors for component manufacturing. No work reported on machinability properties of Titanium oxide (TiO2) and Graphite (Gr) reinforced aluminium composites so far. This study prepared and studied samples composed of variable proportions of titanium oxide and graphite. The samples were prepared using the stir casting method. While stirring, the required additives were added to the molten aluminium mixture. To perform the tests, the samples were prepared according to standard dimensions after solidification. The mechanical properties of the prepared composite were examined using various test procedures, such as strength and hardness. Scanning electron microscopy was used to examine the microstructure of the test composite samples. The EDAX test confirmed the presence of graphite and Titanium oxide in the aluminium based composite specimens. Furthermore, machining was done to study the cutting forces on the tool. The test results showed a significant impact of the reinforced materials on the mechanical and machinability properties of aluminium metal matrix composites. Gr decreases hardness, while TiO2 increases it. TiO2 and Gr reinforcements increase the tensile strength of Al 6061 composites. The addition of TiO2 decreased the composite's elongation. The proof strength of 2 % Al6061 was high, however it decreased with 3 % Gr and increased with TiO2 reinforcement. Reinforcements increase cutting forces during machining; when comparing the machining of Al 6061 to that of 3 % Gr and 5 % TiO2, a 50 % increase in cutting forces is noticed. However, excessive reinforcements may reduce cutting forces due to poor matrix-reinforcement adhesion. HIGHLIGHTS The mechanical and machinability properties of aluminium metal metrics reinforced with Titanium oxide (TiO2) and graphite (Gr) have not been reported so far in the literature. In this study, aluminium based composites reinforced with variable proportions of titanium oxide and graphite were prepared and studied. The fabrication process was done by stir casting by adding the required additives into the molten mixture of aluminium, followed by continuous stirring. The solidified samples were cut according to the standard dimensions and various test procedures were conducted to examine the mechanical and machinability properties of the prepared composites. Gr reduces hardness, whereas TiO2 enhances it. TiO2 and Gr reinforcements boost Al 6061 composite tensile strength. TiO2 addition reduced elongation of the composite. 2 % proof strength of Al 6061 was strong, however it dropped with 3 % Gr and rose with TiO2 reinforcement. Reinforcements results higher cutting forces while machining, however excessive supplements lower cutting forces may be due to poor matrix-reinforcement bonding. GRAPHICAL ABSTRACT

Multi-Objective Optimization of Drilling GFRP Composites Using ANN Enhanced by Particle Swarm Algorithm

This paper aims to optimize the quality characteristics of the drilling process in glass fiber-reinforced polymer (GFRP) composites. It focuses on optimizing the drilling parameters with drill point angles concerning delamination damage and energy consumption, simultaneously. The effects of drilling process parameters on machinability were analyzed by evaluating the machinability characteristics. The cutting power was modeled through drilling parameters (speed and feed), drill point angle, and laminate thickness. The response surface analysis and artificial neural networks enhanced by the particle swarm optimization algorithm were applied for modeling and evaluating the effect of process parameters on the machinability of the drilling process. The most influential parameters on machinability properties and delamination were determined by analysis of variance (ANOVA). A multi-response optimization was performed to optimize drilling process parameters for sustainable drilling quality characteristics. The obtained models were applied to predict drilling process characteristics, and exhibited an excellent harmony with the experiment results. The optimal drilling process factors were the highest spindle speed and the lowest feed, with a drill point angle of 118° for the laminate of 4.75 mm thickness.

Robust PANI@MXene/GQDs Based Fibre Fabric Electrodes via Microfluidic Wet-Fusing Spinning Chemistry.

Two-dimensional (2D) transition metal titanium carbide (Ti3 C2 Tx ) as a promising candidate material for batteries and supercapacitors has shown excellent electrochemical performance, but it is difficult to meet practical applications because of its poor morphology structure, low mechanical properties, and expensive process. Here, w e propose an applied and efficient method based on microfluidic wet-fusing spinning chemistry (MWSC) to construct hierarchical structure of MXene-based fibre fabrics (MFFs), allowing the availability of MFF electrodes with ultra-strong toughness, high conductivity and easily machinable properties. First, a dot-sheet structure constructed by graphene quantum dots (GQDs) and MXene nanosheets with multi-anchor interaction in the microchannel of a microfluidic device enhances the mechanical strength of MXene fibers; next, the interfused fiber network structure of Ti3 C2 Tx /GQDs fabrics assembled by the MWSC process enhances the deformability of the whole fabrics; finally, the core-shell structure of PANI@Ti3 C2 Tx /GQDs architected by in situ polymerization growth of polyaniline (PANI) nanofibers provides more ion-accessible pathways and sites for kinetic migration and ion accumulation. Through the morphology and microstructure design, this strategy has directive significance to the large-scale preparation of conductive fabric electrodes and provides a viable solution for simultaneously enhancing mechanical strength and electrochemical performance of conductive fabric electrodes. This article is protected by copyright. All rights reserved.

Comparison of Machinability Performances in Milling of Al-7Si-Mg and Al-7Si-0.6Mg Alloys

In this study, the microstructural, mechanical and machinability properties of Al-7Si-Mg and Al-7Si-0.6Mg casting alloys were experimentally researched. While the microstructures of the alloys were determined by optical microscope, the hardness values were determined by Brinell method, elongation to fracture, yield (YS) and tensile strength (TS) values were measured by tensile tests. Milling experiments were performed 6 mm diameter of uncoated carbide end mill which two flutes in CNC vertical machining center using different cutting speeds (V), feed rates (f) and a constant depth of cut (DoC). In microstructural examinations, it was observed that the microstructure of the Al-7Si-Mg alloy comprised of a-Al, primary Si, eutectic Al-Si, Mg2Si, B-Al(Fe, Mn)Si, β-Al5FeSi and π-AlSiMgFe phases. In addition to the existing phases, B-Al8Mg3FeSi6 phase was formed in the microstructure of the Al-7Si-0.6Mg alloy. Al-7Si-0.6Mg alloy exhibited higher hardness, YS and TS and lower elongation to fracture (EF) values compared to Al7Si-Mg alloy. In the milling tests, it was stated that the cutting force (CF), built-up layer (BUL) and builtup edge (BUE) reduced with the increment of the V, while it increased with the increment of the

Method for solving bunch head-tail overlapping in HLS-II using a new trigger scanning module of streak-camera measurement system

This study proposed a trigger scanning module for a streak camera to overcome head–tail overlapping of bunch to achieve absolute bunch length monitoring based on the unique machine properties of the Hefei Light Source-II (HLS-II). Furthermore, precise measurement of longitudinal bunch characteristic parameters and study of longitudinal beam dynamics is crucial, and this significantly contributes for observing longitudinal bunch behavior and evolution associated with current potential-well distortion and microwave instability. First, the scanning module is calibrated thoroughly to test its performance and applicability. Afterward, the module is applied to measure the dependence of bunch length on current under single-bunch operation. Moreover, potential-well distortion and bunch lengthening are observed. Results showed that the designed trigger scanning module is appropriate for the exploration of the physical mechanism of single-bunch beam behavior, which is crucial for the investigation of bunch characteristics and beam instability in storage ring light sources.

Performance Evaluation of Graphene Nanofluid to Mitigate the Wear of a Diamond Tool in Micro-Machining of Ti6Al4V Alloy

Diamond tools are extensively used in ultra-precision machining due to their exceptional performance. However, when machining challenging materials like Ti6Al4V, diamond tools experience significant wear due to poor machining properties and catalytic effects. Tool wear not only impacts machining quality but also escalates machining costs and energy consumption. Cutting fluids are commonly employed to mitigate interfacial reactions and suppress tool wear. However, traditional cutting fluids are difficult to penetrate the cutting area and have limited lubrication and cooling capabilities. Therefore, in this paper, a technique combining graphene nanofluid and minimum-quantity lubrication (MQL) is used to suppress diamond tool wear. Firstly, micro-milling experiments for Ti6Al4V alloy are conducted using diamond tools in the graphene nanofluid MQL and under a dry environment. The experimental results show that tool wear is effectively suppressed by graphene nanofluids. Subsequently, the cutting process in both environments (graphene nanofluid MQL, dry) is simulated. The suppression mechanism of graphene nanofluid MQL for diamond tool wear is evaluated from phase transition, atomic transfer process, and amorphous behavior of diamond structure. The simulation results show that the contact characteristics, cutting force, and cutting temperature are improved by graphene nanofluids. Tool wear is effectively reduced. In addition, the removal efficiency of workpiece materials has also been improved. This work provides a technical basis for exploring the application of graphene nanofluids in diamond tool damage suppression and micro-milling.