Minimum quantity lubrication machining nickel base alloy: a comprehensive review

Zhou, Shu; Wang, Dazhong; Wu, Shujing; Gu, Guquan; Dong, Guojun; An, Qinglong; Guo, Hun; Li, Changhe

doi:10.1007/s00170-023-11721-6

Cited by 19 publications

(5 citation statements)

References 178 publications

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“…In the metal cutting process, choosing the right cutting fluid can improve the cooling and lubrication performance, further reduce the friction in the machining process, and thus improve tool life, machining efficiency, and surface quality. Currently, the common approach of using cutting fluid in the machining process is still flooding, and the use of flooding cutting fluid accounts for 7%-18% of the total cost of the machining process [4][5][6]. Moreover, traditional flooded metalworking fluids are usually made from nonrenewable mineral oils and scarce water resources.…”

Section: Introductionmentioning

confidence: 99%

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Hu,

Li,

Zhou

et al. 2023

Front. Mech. Eng.

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Nanoparticle-enhanced coolants (NPECs) are increasingly used in minimum quantity lubrication (MQL) machining as a green lubricant to replace conventional cutting fluids to meet the urgent need for carbon emissions and achieve sustainable manufacturing. However, the thermophysical properties of NPEC during processing remain unclear, making it difficult to provide precise guidance and selection principles for industrial applications. Therefore, this paper reviews the action mechanism, processing properties, and future development directions of NPEC. First, the laws of influence of nano-enhanced phases and base fluids on the processing performance are revealed, and the dispersion stabilization mechanism of NPEC in the preparation process is elaborated. Then, the unique molecular structure and physical properties of NPECs are combined to elucidate their unique mechanisms of heat transfer, penetration, and antifriction effects. Furthermore, the effect of NPECs is investigated on the basis of their excellent lubricating and cooling properties by comprehensively and quantitatively evaluating the material removal characteristics during machining in turning, milling, and grinding applications. Results showed that turning of Ti–6Al–4V with multi-walled carbon nanotube NPECs with a volume fraction of 0.2% resulted in a 34% reduction in tool wear, an average decrease in cutting force of 28%, and a 7% decrease in surface roughness Ra, compared with the conventional flood process. Finally, research gaps and future directions for further applications of NPECs in the industry are presented.

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Section: Introductionmentioning

confidence: 99%

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Hu,

Li,

Zhou

et al. 2023

Front. Mech. Eng.

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“…Due to the poor thermal conductivity of nickel-based alloys, there are certain limitations to MQL when processing such materials. To address the deficiencies related to friction control and heat generation, Nano-fluid MQL has been proposed to overcome these challenges [69][70][71]. Nano-particles not only enhance thermal conductivity but also exhibit the effects of ball bearings and polishing, forming a protective lubricating film at the processing interface (Figure 10).…”

Section: Nanofluid Mql Processing Of Nickel-based Alloysmentioning

confidence: 99%

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Gu,

Wang,

et al. 2024

Intelligent and Sustainable Manufacturing

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Nickel-based alloys has important application value in modern industrial field, but there are a lot of problems that are difficult to solve in traditional processing, and it is a typical difficult-to-process material. In order to improve the machinability of nickel-based alloys, scholars try to use a variety of non-traditional processing methods to explore and study the processing of nickel-based alloys. In these studies, ultrasonic vibration assisted processing technology and minimum quantity lubrication (MQL) processing technology can achieve remarkable results. The intermittent separation cutting characteristics of ultrasonic vibration assisted processing technology can improve the processing quality by changing the tool path, while minimum quantity lubrication processing technology can improve the lubrication effect of cutting, combining ultrasonic vibration assisted MQL processing leverages the benefits of both methods, resulting in improved machinability and expanded application of nickel-based alloys. Summarize the current research status on the machining mechanism of nickel-based alloys assisted by ultrasonic vibration and micro lubrication, and anticipate its developmental trends. This provides a reference for future research on the efficient machining mechanisms and practical applications of nickel-based alloys.

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“…Nickel-based alloys occupy an important position in the engineering field due to their unique mechanical, thermal and chemical properties. Due to its excellent high-temperature performance, it is often used in gas turbines, jet engines and other aerospace components [51]. In addition, its excellent corrosion resistance makes it particularly suitable for chemical and marine environments.…”

Section: Nickel-based Alloysmentioning

confidence: 99%

“…In comparison to dry machining, the decrease in grinding temperature achieved through NMQL was double that of pure oil cutting fluid MQL. Zhou et al [51] conducted a review The concept of nanofluids was first proposed by Choi of Argonne Laboratory in the United States in 1995 [34]. Nanofluids are affected by the type, size, shape, preparation method and additives of nanoparticles.…”

Section: Introductionmentioning

confidence: 99%

“…In comparison to dry machining, the decrease in grinding temperature achieved through NMQL was double that of pure oil cutting fluid MQL. Zhou et al [51] conducted a review on the utilization of nano-cutting fluids in the cutting of nickel-based alloys. Numerous experimental results indicate that NMQL enhances surface quality, extends tool lifespan, lowers processing temperature, and boosts processing efficiency in nickel-based alloy machining.…”

Section: Introductionmentioning

confidence: 99%

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Nanofluids Minimal Quantity Lubrication Machining: From Mechanisms to Application

Chu,

Li,

Zhou

et al. 2023

Lubricants

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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.

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Minimum quantity lubrication machining nickel base alloy: a comprehensive review

Cited by 19 publications

References 178 publications

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Nanofluids Minimal Quantity Lubrication Machining: From Mechanisms to Application

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