International Journal of Nanoscience and Nanotechnology

International Journal of Nanoscience and Nanotechnology

An investigation of nanofluid MQL on surface roughness and total cutting force in hard turning process using CBN inserts

Document Type : Research Paper

Authors
Pham Quang Dong 1
Tran Bao Ngoc 2
Ngo Minh Tuan 1
Tran Minh Duc 1
Tran The Long 1
1 Department of Manufacturing Engineering, Faculty of Mechanical Engineering, Thai Nguyen University of Technology, Thai Nguyen 250000, Vietnam
2 Department of Fluids Mechanic, Faculty of Automotive and Power Machinery Engineering, Thai Nguyen University of Technology, Thai Nguyen 250000, Vietnam
10.22034/ijnn.2025.2043557.2584
Abstract
The growing demand for environmentally friendly solutions for improving hard machining performance is considered as the urgent issue in modern manufacturing. Nanofluid minimum quantity lubrication (NF MQL) has emerged as a promising technique to enhance cooling and lubrication effectiveness in cutting zone, thereby improving hard cutting performance. This paper aims to study the effects of Al2O3 nanofluid MQL hard turning using CBN inserts on surface roughness and total cutting force. Box–Behnken experimental design for response surface methodology was used to investigate the influences of nanoparticle concentration, air flow rate, and air pressure on the responses. The obtained results revealed that the performance of hard turning process was improved by using Al2O3 nanofluid MQL environment. The technological guides were provided for the specific cutting conditions. Specifically, nanoparticle concentration of 0.5%, air pressure of 4.9 bar, and flow rate of 150 l/min is determined as the optimal set for lowest total cutting force (Fr =153.36N). Besides, nanoparticle concentration NC = 0.54%, air pressure p = 5.1 bar, and air flow rate Q = 250 l/min should be used for the minimum surface roughness (Ra = 0.288µm). Furthermore, based on the multi-optimization results, an optimal parameter set (NC = 0.53%, p = 4.79 bar, and Q = 193.4 l/min) should be suggested to achieve the minimal values of Ra=0.2987 µm and Fr =169.16 N.
Keywords
Hard turning
Nanofluid
MQL
Al2O3 Nanoparticles
Surface Roughness
Total Cutting Force

Subjects

  1. REFERENCES

    1. Davim, J. P., “Machining of Hard Metals”, Springer-Verlag London Limited, (2011), https://doi.org/10.1007/978-1-84996-450-0.
    2. Patel, G. C. M., Chate, G. R., Parappagoudar, M. B., Gupta, K., “Machining of Hard Materials (A Comprehensive Approach to Experimentation, Modeling and Optimization)”, Springer International Publishing, (2020), doi:10.1007/978-3-030-40102-3.
    3. Ali, S. H., Yao, Y., Wu. B, Zhao, B., Ding, W., Jamil, M., Khan, A., Baig, A., Liu, Q., Xu, D., “Recent developments in MQL machining of aeronautical materials: A comparative review”, Chinese Journal of Aeronautics, 38 (1) (2025) 102918, https://doi.org/10.1016/j.cja.2024.01.018.
    4. He, T., Liu, H., Xia, H., Wu, L., Zhang, Y., Li, D., Chen, Y., “Progress and trend of minimum quantity lubrication (MQL): A comprehensive review”, Journal of Cleaner Production, 386 (1) (2023) 135809, https://doi.org/10.1016/j.jclepro.2022.135809.
    5. Balasuadhakar, A., Kumaran, S. T., Ahmed, F., “A review on the role of nanoparticles in MQL machining”, Materials Today: Proceedings, 72 (6) (2023) 2828-2832, https://doi.org/10.1016/j.matpr.2022.07.247.
    6. Rahman, S. S., Ashraf, M. Z. I., Amin, A. K. M. N., Bashar, M. S., Ashik, M. F. K., Kamruzzaman, M., “Tuning nanofluids for improved lubrication performance in turning biomedical grade titanium alloy”, Journal of Cleaner Production, 206 (2019) 180–196, doi:10.1016/j.jclepro.2018.09.150.
    7. Hegab, H., Umer, U., Soliman, M., Kishawy, H. A., “Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718”, The International Journal of Advanced Manufacturing Technology, 96 (9–12) (2018) 3449–58, doi:10.1007/s00170-018-1825-0.
    8. Darshan, C., Jain, S., Dogra, M., Gupta, M. K., Mia, M., “Machinability improvement in Inconel-718 by enhanced tribological and thermal environment using textured tool”, Journal of Thermal Analysis and Calorimetry, 138 (1) (2019) 273–285, doi:10.1007/s10973-019-08121-y.
    9. Gupta, M. K., Jamil, M., Wang, X., Song, Q., Liu, Z., Mia, M., Hegab, H., Khan, A. M., Collado, A. G., Pruncu, C. I., Imran, G. M. S., “Performance Evaluation of Vegetable Oil-Based Nano-Cutting Fluids in Environmentally Friendly Machining of Inconel-800 Alloy”, Materials, 12 (17) (2019) 2792, doi:10.3390/ma12172792.
    10. Sharma, A. K., Tiwari, A. K., Dixit, A. R., “Effects of Minimum Quantity Lubrication (MQL) in machining processes using conventional and nanofluid based cutting fluids: A comprehensive review”, Journal of Cleaner Production, 127 (2016) 1-18, doi.org/10.1016/j.jclepro.2016.03.146.
    11. Leong, K. Y., Ahmad, K. Z. K., Ong, H. C., Ghazali, M. J., Baharum, A., “Synthesis and thermal conductivity characteristic of hybrid nanofluids – A review”, Renewable and Sustainable Energy Reviews, 75 (2017) 868-878, doi: 10.1016/j.rser.2016.11.068.
    12. Zhang, Y., Li, C., Jia, D., Zhang, D., Zhang, X., “Experimental evaluation of MoS2 nanoparticles in jet MQL grinding with different types of vegetable oil as base oil”, Journal of Cleaner Production, 87 (2015) 930–940, doi:10.1016/j.jclepro.2014.10.027.
    13. Uysal, A., Demiren, F., Altan, E., “Applying Minimum Quantity Lubrication (MQL) Method on Milling of Martensitic Stainless Steel by Using Nano MoS2 Reinforced Vegetable Cutting Fluid”, Procedia - Social and Behavioral Sciences, 195 (2015) 2742–2747, doi:10.1016/j.sbspro.2015.06.384.
    14. Yücel, A., Yıldırım, Ç. V., Sarıkaya, M., Şirin, Ş., Kıvak, T., Gupta, M. K., Ítalo, V. T., “Influence of MoS2 based nanofluid-MQL on tribological and machining characteristics in turning of AA 2024 T3 aluminum alloy”, Journal of Materials Research and Technology, 15 (2021) 1688–1704, https://doi.org/10.1016/j.jmrt.2021.09.007.
    15. Rahmati, B., Sarhan, A. A. D., Sayuti, M., “Morphology of surface generated by end milling AL6061-T6 using molybdenum disulfide (MoS2) nanolubrication in end milling machining”, Journal of Cleaner Production, 66 (2014) 685–691, doi:10.1016/j.jclepro.2013.10.048.
    16. Park, K. H., Olortegui-Yume, J. A., Joshi, S., Kwon, P., Yoon, M. C., Lee, G. B., Park, S. B., “Measurement of Droplet Size and Distribution for Minimum Quantity Lubrication (MQL)”, IEEE 2008 International Conference on Smart Manufacturing Application, (2008) 447–454, doi:10.1109/icsma.2008.4505598.
    17. Sharma, A. K., Tiwari, A. K., Dixit, A. R., “Mechanism of Nanoparticles Functioning and Effects in Machining Processes: A Review”, Materials Today: Proceedings, 2 (4-5) (2015) 3539–3544, doi:10.1016/j.matpr.2015.07.331.
    18. Maruda, R. W., Arkusz, K., Szczotkarz, N., Wojciechowski, S., Niesłony, P., Królczyk, G. M., “Analysis of size and concentration of nanoparticles contained in cutting fluid during turning of 316L steel in minimum quantity lubrication conditions”, Journal of Manufacturing Processes, 87 (2023), https://doi.org/10.1016/j.jmapro.2022.12.065.
    19. Szczotkarz, N., Maruda, R., Leksycki, K., Feldshtein, E., Wojciechowski, S., Jurczak, P., Waligóra, M., “Analysis of Power Grid Parameters Depending on the Variable Concentration and Size of Copper Nanoparticles and Aerosol Formation Parameters in the Minimum Quantity Lubrication Method During Turning of Ti6Al4V Titanium Alloy”, Advances in Science and Technology Research Journal, 17 (6) (2023) 315-324, https://doi.org/10.12913/22998624/174806.
    20. Abbas, A. T., Gupta, M. K., Soliman, M. S., Mia, M., Hegab, H., Luqman, M., Pimenov, D. Y., “Sustainability assessment associated with surface roughness and power consumption characteristics in nanofluid MQL-assisted turning of AISI 1045 steel”, The International Journal of Advanced Manufacturing Technology, 105 (1-4) (2019) 1311–1327. doi:10.1007/s00170-019-04325-6.
    21. Wang, Y., Li, C., Zhang, Y., Li, B., Yang, M., Zhang, X., Guo, S., Liu, G., “Experimental evaluation of the lubrication properties of the wheel/workpiece interface in MQL grinding with different nanofluids”, Tribology International, 99 (2016) 198–210, doi:10.1016/j.triboint.2016.03.02.
    22. Luo, T., Wei, X., Huang, X., Huang, L., Yang, F., “Tribological properties of Al2O3 nanoparticles as lubricating oil additives”, Ceramics International, 40 (5) (2014) 7143–7149, doi:10.1016/j.ceramint.2013.12.05.
    23. Duc, T. M., Long, T. T., Ngoc, T. B., “Effectiveness of alumina nanofluid on slotting end milling performance of SKD 11 tool steel”, Comput. Appl. Res. Mech. Eng., 9 (2) (2020) 359-369, doi: 10.22061/JCARME.2019.4041.1484.
    24. Duc, T. M., Long, T. T., Dong, P. Q., “Effect of the alumina nanofluid concentration on minimum quantity lubrication hard machining for sustainable production”, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 233 (2019) 5977–5988, doi:10.1177/0954406219861992.
    25. Eltaggaz, A., Zawada, P., Hegab, H. A., Deiab, I., Kishawy, H. A., “Coolant strategy influence on tool life and surface roughness when machining ADI”, J. Adv. Manuf. Technol., 94 (2018) 3875–3887, https://doi.org/10.1007/s00170-017-1088-1.
    26. Hegab, H., Umer, U., Soliman, M., Kishawy, H. A., “Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718”, The International Journal of Advanced Manufacturing Technology, 96 (9-12) (2018) 3449–3458, doi:10.1007/s00170-018-1825-0.
    27. Cheraghian, G., “Application of Nano-Particles of Clay to ‎Improve Drilling Fluid”, International Journal of Nanoscience and Nanotechnology, 13 (2) (2017) 177-186.
    28. Günan, F., Kıvak, T., Yıldırım, Ç. V., Sarıkaya, M., “Performance evaluation of MQL with Al2O3 mixed nanofluids prepared at different concentrations in milling of Hastelloy C276 alloy”, Journal of Materials Research and Technology, 9 (5) (2020) 10386–10400, doi:10.1016/j.jmrt.2020.07.018.
    29. Madanirad, Z., Akbari, M., Shariaty-Niassar, M., Abadi, K. A. V., “Effects of Graphene Oxide Size on PES ‎Ultrafiltration Hydrophilicity and Pure ‎Water Flux”, International Journal of Nanoscience and Nanotechnology, 19 (2) (2023) 121-134, doi: 10.22034/ijnn.2023.2001625.2372.
    30. Ngoc, T. B., Duc, T. M., Tuan, N. M., Hoang, V. L., Long, T. T., “Machinability Assessment of Hybrid Nano Cutting Oil for Minimum Quantity Lubrication (MQL) in Hard Turning of 90CrSi Steel”, Lubricants, 11 (2023) 54, https://doi.org/10.3390/lubricants11020054.
International Journal of Nanoscience and Nanotechnology
Volume 20, Issue 4
2024
Pages 249-260