Machining feasibility and Sustainability study associated with air pressure, air flow rate, and nanoparticle concentration in Nanofluid minimum quantity lubrication-assisted hard milling process of 60Si2Mn steel

Abstract

In recent years, more efficient hard machining processes have notably increased in demand for higher productivity but environmental friendliness. High hardness and strength as well as the enormous amount of cutting temperature are still the biggest obstacles. Nanofluid minimum quantity lubrication (NFMQL)–assisted hard machining has become a feasible and promising solution to overcome these problems. The work presents the experimental study on the effects of air pressure (5, 6, and 7 bar), air flow rate (150, 200, and 250 L/min), and Al2O3 nanoparticle concentration (0.5, 1.0, and 1.5%) on minimum quantity lubrication (MQL) hard milling process of 60Si2Mn (50÷52HRC) using vegetable oil as the based fluid. Box–Behnken experimental design and ANOVA analysis were employed to investigate the influences and interaction effects of input parameters on cutting forces, surface roughness, and surface microstructure. This study will be used for selecting the optimum air pressure, air flow rate, and Al2O3 nanoparticle concentration for efficient cooling lubrication performance of MQL in sustainable hard machining. The obtained results show that the optimal values for air pressure and nanoparticle concentration. For Q = 200 L/min, the optimal p is 6.0 bar and the optimal nanoparticle concentration (NC) is 0.9%. For Q = 250 L/min, the optimal p is 5.2 bar, and the optimal NC is 1.2%. Furthermore, using air flow rate Q = 250 L/min gives better results than Q = 200 L/min, but the selection will be depended on the specific equipment conditions.

Optimization of Al2O3 nanoparticle concentration and cutting parameters in hard milling under nanofluid MQL environment

“…The MQL system includes: NOGA MiniCool MC1700 combined with the air pressure regulator, and air flow rate valve, PT-0136 compressed air, soybean oil, and Al 2 O 3 nanoparticles (30 nm). 28 The external MQL nozzle was chosen due to the ease to apply in practice and the modification of the machine tool is not required. It was mounted to directly spray on the flank face of cutting tool with spray angle of 12° and nozzle distance of 55 mm.…”

“…29 Ultrasons-HD (JP SELECTA in Spain) is used to create ultrasonic vibration in at least 50 min in advance in order to ensure the homogeneity of Al 2 O 3 nanoparticles in the soybean oil. 28 Then, the obtained nano cutting oils were directly used for MQL system to avoid the precipitation of agglomerated nanoparticles during the long machining time. Kistler quartz three-component dynamometer (9257BA) and SJ-210 Mitutoyo (made by Japan) were used for measuring cutting forces and surface roughness (cut-off length of 0.08 mm).…”

“…The improved lubrication efficiency by using nano cutting oils helps to reduce cutting forces, tool wear, and improves the machinability of carbide inserts. After that, the authors conducted a further study on the effects of flow rate and air flow pressure of MQL using nano-cutting oil on cutting forces, surface integrity, and determined the optimal values, 14,28 which are used for this study. The obtained results presented in this work aim to evaluate the effects of Al 2 O 3 nanoparticle concentration, cutting speed, and feed rate on the surface roughness R z and total cutting force, from which the appropriate value ranges and the optimal set can be determined for further studies and production practice.…”

WASPAS Based Multi Response Optimization in Hard Turning of AISI 52100 Steel under ZnO Nanofluid Assisted Dual Nozzle Pulse-MQL Environment

“…The greatest challenges remain higher hardness strength, and a significant cutting temperature. To address these issues, NFMQL (nanofluid minimum quantity lubrication)-assisted hard part machining has emerged as a viable process [7]. Because of environmental concerns about the use and disposal of cutting fluids during machining, the MQL approach was developed, which necessitates the use of specialized fluids with better qualities.…”