Effect of tri-hybridized metallic nano cutting fluids in end milling of AA7075 in minimum quantity lubrication environment

Abstract

The current paper is concentrated on the mechanical and machining process exploration of metallic nano-lubricant with the concept of tri-hybridization with improved lubricative and cooling properties by using TiO2, ZnO and Fe2O3 metallic nano particles with neat cold-pressed coconut oil in a fixed volumetric proportion (10:90). End milling of gummy material like aluminium requires a solution to the conventional dry and wet machining due to high productivity requirement and to obtain good surface quality. So, the prepared nanofluids were tested for their rheological behavior and latter introduced into milling of AA7075 as a solution to the above stated problem. Overall, the nanofluids gave good performance when compared to conventional methods. Furthermore, the results obtained from the experiments confirm that the trio-hybridized lubricant has reduced the cutting force, tool wear and surface roughness in an improved way when related to monotype nano fluids. The response surface methodology is performed to evaluate the interaction of process parameters in minimum quantity lubrication environment with nano fluids. The results show that the cutting forces, surface roughness, tool wear was minimized while machining with hybrid cutting fluids and well within the desirability.

Application of tri-hybridized carbonaceous nanocutting fluids in an end milling operation by the minimum quantity lubrication technique

“…The results obtained with the prepared nanofluids shows a dip in the cutting temperature. This goes well with the previous research works 29,44 and it is attributed to the better cooling and lubrication properties of nanofluids. In addition, formation of a filmy layer provides better thermal conductivity to the nanofluid absorbing the heat generated.…”

“…Larger chipping was observed while machining with h-BN and graphene and lower chipping in MWCNT and tri-hybrid nanofluids. 29 This novel comparison is found to be effective.…”

“…The levels of the trials are shown in Table 5. Considering the gummy nature of the material and based on previous research works, 29 the depth of cut was fixed (1.5 mm) as the study is focused toward analyzing the performance and finding the best among the considered carbonaceous nanofluids. Considering the novel concept of merging high-speed machining under nanocutting fluids-MQL condition high levels and low levels were chosen for speed and feed rates.…”

“…This is at par with previous research works. 29,40,41 The microscopic images of the flank face of the tool shown in Figure 11 (a) to (d) reveal that fracture due to thermal shocks and tool fracture has been exterminated. Feed marks and tool chipping was observed to a small extent in tri-hybrid nanofluids when compared to other nanofluids.…”

Grindability study of hard to cut AISI D2 steel upon ultrasonic vibration-assisted dry grinding

“…On the contrary, coolants have a significant drawback, such as the pernicious impact on the machine operator’s health, environmental hazards, and enhanced the cost of manufacturing. 1,2 To reduce the adverse environmental effect of the coolants and also to reduce manufacturing costs, dry grinding methods are used, wherever possible. Usually, in traditional dry grinding (TDG), there is absence of lubricant to carry away heat from the overheated grinding region.…”