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Nonedible vegetable oil-based cutting fluids for machining processes – a review
Materials and Manufacturing Processes
Abstract
Cutting fluids are an inherent part of the modern manufacturing system. With the increase in the industrialization and development of new materials and processes, there has been a need for developing new cutting fluids with superior performance. For achieving this, cutting fluids have been produced from mineral oil and other additives. The additives used in the cutting fluids are carcinogenic in nature and are harmful to the workers and the environment. Mostly edible oils have been used as cutting fluids in machining. But it has been seen that nonedible oils have the potential to be used in the manufacturing sector to mitigate the detrimental effects of conventionally used cutting fluids without compromising on machining efficiency. The purpose of this review article is to apprise the readers with the current trend in the application of nonedible vegetable oils and their application in machining. This paper entails various aspects of cutting fluids and an up to date and exhaustive review on the latest literature on the effectiveness of nonedible oils and its modified versions, blended oils, ionic liquids, and nanoparticles as additives is done to understand the efficacy of nonedible vegetable oil-based cutting fluids.
... Furthermore, the combined use of biodegradable coolant, air and liquid nitrogen enhance the machinability indices in machining of supper-alloys [5,30]. However, expensive apparatus are required for the handling of gas-based coolants [5,31]. Therefore, more concentration is required on this aspect reported by researchers for further studies. ...
... Therefore, more concentration is required on this aspect reported by researchers for further studies. Table 1 provides a complete summary of conventional coolants [31]. ...
... Summary of conventional coolants[31]. ...
... The CFs work as a cooling agent to limit the increased temperatures while grinding by reducing the frictional resistance with their lubricating properties and removing powdered chips from the grinding area, which helps to avoid burns and improve the surface finish [15][16][17]. They also shield the workpiece from corrosion and cool it to make handling and inspection easier [18][19][20]. ...
... This will help enhance the sustainability of the cashew nut processing industry, as cashew shells are the agro-waste from which the CNSL is extracted. It can be appreciated as it is non-edible, cheaply available, and will not harm food security [20,37]. Prasannakumar et al [38] checked the viability of using CNSL, an inexpensive and plentiful non-edible oil, as a lubricant material. ...
The current work advocates the use of Cashew Nut Shell Liquid/Oil (CNSL), an oil extract of the leftover cashew nut shells, as a novel environment-friendly cutting fluid in sustainable machining operations. The tribological characteristics of CNSL obtained on a pin-on-disc tribometer are found to be better compared to the traditionally used cutting fluid. Experiments are conducted on the surface grinder with EN8 material, considering input parameters, such as cutting fluid type, grinder speed and grade, work speed, and depth of cut, with Surface Roughness (Ra) and Grinding Temperature (Temp) being the responses. Input parameter optimization is performed using Taguchi’s statistical models. A total of 36 investigative and six validation experiments are conducted, and a prediction model is proposed. When Ra and Temp are optimized simultaneously, the prediction value of Ra is 0.071 μm, and the corresponding value of Temp is 31.6 °C for which the experimental values are 0.072 μm and 32 °C respectively. This work also applies the TODIM (TOmada de Decisao Interativa Multicriterio, in the Portuguese language), a multi-attribute decision-making method for ranking the input parameter settings. The study reveals that the performance of CNSL is better than that of a traditional cutting fluid, and the TODIM method can be successfully applied to rank the input parameter settings.
... Unfortunately, most additives employed in industry are noxious to the environment or human health. More recently, looking for better performance and environmental care, other research groups have studied the addition of different nanoparticles (i.e., TiO2 [6], polyethyleneimine-reduced graphene oxide nanosheets [7], etc.), ionic liquids [8,9] and bio-derived oils to produce water-based lubricants and green emulsions [10][11][12]. The use of bio-derived oils as additives has received increased attention since water-based lubricants in the form of green emulsions are extensively used in the global manufacturing industry as metalworking fluids (MWFs) for lubricating machining/cutting/removal processes. ...
... (www.preprints.org) | NOT PEER-REVIEWED | Posted: 29 January 2024 doi:10.20944/preprints202401.1942.v111 ...
The recent green manufacturing demands have boosted the development of new biodegradable lubricants to replace petroleum-based lubricants. In this regard, water-based lubricants have been at the forefront of recent research for a wide range of industrial applications, including metalworking fluids (MWFs). In this work, we present an experimental investigation on the performance of novel green MWFs based on aqueous nopal mucilage solutions. For this, fully biodegradable solutions with different mucilage concentrations were evaluated in terms of rheological, tribological, thermal stability and turning (minimum quantity lubrication) performance, and compared to a commercial semisynthetic oil-based MWF (Cimstar 60). Mucilage solutions exhibited viscoelastic shear-thinning behavior, which was enhanced along with mucilage concentration. The solution with the highest mucilage content studied resulted in the lowest wear, friction and temperature in comparison to the other solutions and neat water in extreme pressure four-ball tests, and a similar level of lubricity as compared to the commercial MWF in cutting tests. This performance is associated to the enhanced viscosity and elasticity of the solution, as well as to the contents of lipids with fatty acids in the mucilage. Overall, the present results reveal the relevance of the viscoelastic behavior of the lubricant, elasticity in particular, in lubrication processes, and points to nopal mucilage as an effective green additive to produce innocuous MWFs.
... Cutting fluids limit the excessive temperature increase during machine operations (Katna et al., 2020). Although mineral oils are cheaper, they perform poorly due to lower pour points, oxidation instability, and viscosity loss under higher temperatures. ...
... A safe reintroduction of biomaterial into the natural carbon cycle is ensured by biodegradability. In naturally occurring climatic circumstances, non-edible vegetable oils deteriorate more quickly than mineral oils (Katna et al., 2020). ...
... According to reports, the amount of metal working fluids (MWF) consumed in 2018 was 39.4 million Mt, and that in 2022, number rose approximately to 43.9 million Mt. The three primary purposes of metalworking/cutting fluids are to: (a) lubricate throughout the cutting process to decrease friction and lengthen the lifetime of the parts; (b) cool cutting components and work equipment to eliminate heat while reducing wear, and (c) improve workpiece quality by removing chips from cutting components and equipment [166,167]. Since metal working fluid is based on petroleum, both the environment and employees' health are at risk when it is used. In addition, the hazardous substances included in MWF result in skin sensitization and the intake of dispersed metal flux particles, cause cancer in employees and pulmonary system damage [168,169]. ...
... Another study was conducted by Wickramasinghe et al. and it was revealed that the application of vegetable-oil-based machining fluid in the welding industry ensured the health of workers and the environment because it offered the desired level of performance in the metal cutting and desirable characteristics for renewability and biodegradability [171]. Non-edible oils have a significant potential to replace mineral based cutting lubricants because of their better efficiency, enhancing tool life, reducing energy consumption, and lowering COF, according to scientific studies [167]. ...
... Second, these fluids have exceptional heat dissipation qualities that make it easier to cool both cutting tools and workplace equipment, reducing heat-related damage. By efficiently eliminating chips from the cutting tool and equipment, they also help to improve the quality of the workpiece (Katna et al. 2020). Cottonseed oil stands out as a promising contender for MWF, surpassing the traditional industry standard MWF. ...
Lubricants are pivotal in mitigating friction and wear between surfaces, ensuring seamless movement of solid objects. However, the predominant use of petroleum-based lubricants in the automotive and industrial ssectors raises substantial concerns for future energy security. The exploration of vegetable oils as an alternative lubricant in the automotive industry was motivated by the depletion of fossil fuels and escalating environmental concerns. The post-pandemic surge in environmental awareness has intensified the focus on biolubricants. Over the past two decades, the biolubricants field has burgeoned with numerous research, signaling a heightened interest in eco-friendly and sustainable lubrication solutions. This underscores biolubricants as a dynamic and evolving research area with lasting prominence, especially amid ongoing environmental innovation. The review centrally revolves around naturally sourced lubricants, primarily focusing on vegetable oils, which stand out as appealing substitutes for conventional petroleum-based lubricants due to their biodegradability, high lubricity, and elevated flash points. The article delves into modifications to enhance vegetable oil properties, explores the role of additives, and provides insights into current and future prospects. The paper also investigates diverse applications in engine oil, grease, hydraulic oil, and more.
... Nevertheless, vegetable oils come with certain drawbacks, including low oxidative stability, poor thermal stability, and bad anti-corrosion characteristics [122]. Many studies in the literature indicate that CFs based on vegetable oils exhibit superior performance and are more readily biodegradable [129,130]. ...
... Coolant has to be processed and treated before it can be disposed. This method almost doubles the cost of production and the cost, covering around 7% to 17% of the total cost [9]. Even though the price of coolants is high, these substances can still generate toxic fumes, which can cause respiratory issues and even cause cancer for the operators [10]. ...
This study investigates the impact of various auxiliary cooling techniques on machinability, energy consumption, carbon emissions, and economic factors in the drilling process of AA7075T6 aluminium alloy using TiO2 and C-reinforced composites. The study employed various cooling conditions (dry, MQL, CO2, and hybrid MQL+CO2), with different cutting speeds and feed rates, to evaluate their effects on drilling characteristics. The findings indicated that the combined MQL and CO2 cooling notably enhanced the drilling process by reducing cutting forces by 32% and surface roughness by 65% compared to dry cutting. This synergy between lubrication and cooling significantly improves machinability, resulting in higher-quality machining outputs with smoother surfaces and more precise circularity. Energy analysis revealed that the MQL+CO2 method reduces energy consumption to 64% observed under dry conditions, underscoring its efficiency through better heat dissipation and reduced friction. Furthermore, this method demonstrates a significant reduction in carbon emissions, contributing to environmental sustainability. Economically, although initial costs associated with the implementation of cooling systems are higher, they are offset by reduced tool wear and energy costs, making it a viable solution for sustainable manufacturing practices.
... Unfortunately, most additives employed in industry are noxious to the environment or human health. More recently, looking for better performance and environmental care, other research groups have studied the addition of different nanoparticles (i.e., TiO 2 [6], polyethyleneimine-reduced graphene oxide nanosheets [7], etc.), ionic liquids [8,9], and bio-derived oils to produce water-based lubricants and green emulsions [10][11][12]. The use of bio-derived oils as additives has received increased attention since water-based lubricants in the form of green emulsions are extensively used in the global manufacturing industry as metalworking fluids (MWFs) for lubricating machining, cutting, and removal processes. ...
Recent green manufacturing demands have boosted the development of new biodegradable lubricants to replace petroleum-based lubricants. In this regard, water-based lubricants have been at the vanguard of recent research for a wide range of industrial applications, including metalworking fluids (MWFs). In this work, we present an experimental investigation on the performance of novel green MWFs based on aqueous nopal mucilage solutions. For this, fully biodegradable solutions with different mucilage concentrations (2.29, 4.58, and 6.85 mg/mL) were evaluated in terms of rheological, tribological, thermal stability, and turning (minimum quantity lubrication) performance and compared to a commercial semisynthetic oil-based MWF (Cimstar 60). Mucilage solutions exhibited viscoelastic shear-thinning behavior, which was enhanced along with mucilage concentration. The solution with the highest mucilage content studied resulted in the lowest wear, friction, and temperature in comparison to the other solutions and neat water in extreme pressure four-ball tests and a similar level of lubricity as compared to the commercial MWF in cutting tests. This performance is associated with the enhanced viscosity and elasticity of the solution, as well as the contents of lipids with fatty acids in the mucilage. Overall, the present results reveal the relevance of the viscoelastic behavior of the lubricant, elasticity in particular, in lubrication processes and point to nopal mucilage as an effective green additive to produce innocuous MWFs.
... Due to the technology improvement, the usage of cutting fluid is optimized by providing a small amount of lubricant called MQL, which enhances the machining quality by reducing the CF and improving the surface roughness (Ra) of the products. In addition, to minimize heat generation, various types of oil, such as animal fat, vegetable oil, or lard, can be used as a lubricant and a coolant due to their excellent heat convection properties [12]. Krishnan and Raj [13] conduct drilling AISI 304 under different cooling environments. ...
Both the product and the manufacturing process must be sustainable in today's modern world. Traditional machining methods are undesirable when working with heat-resistant alloys. These methods could be more efficient and can be maintained over time. As the world progresses to sustainability, many people are working to integrate this concept into the industrial process. In the manufacturing industry, the evaluation of sustainability carries immense significance in ensuring product quality, promoting operators' safety and well-being, and preventing any form of environmental degradation or pollution. Concerning this regard, the main objective of the present study is to assess the sustainability parameters during the drilling of Alloy 20 material under different environmental conditions such as minimum quantity lubrication (MQL) and cryogenic and hybrid methods. The study is conducted in two stages, and in the first stage, the most impactful sustainable indicators, i.e., energy consumption, carbon emissions, total cycle time, and cost, have been evaluated. In the second phase of the investigation, the machining analysis of surface roughness, cutting forces, and circularity was determined under different conditions. The results showed that the hybrid cooling condition exhibited better technical, quality, and economic sustainability. Thus, it is important to note that selecting appropriate cooling conditions can contribute to achieving sustainability in manufacturing processes and that the hybrid cooling method aids industries in moving towards sustainable production systems that, in turn, contribute to a more environmentally conscious and efficient economy.
... 21 This technique has also eliminated the disposal problem as almost all the amount of cutting fluid is evaporated. 22,23 Sharma et al. 24 investigated the effects of lubrication conditions and cutting parameters on cutting force, tool wear, and surface roughness in AISI 1040 turning and wet lubrication conditions. Singh et al. 25 investigated the effects of nanoparticle types on thermal conductivity and thermal capacities at different temperatures. ...
This study focused on determining the effects of the cooling condition in the conventional and ultrasonic-assisted turning of AISI 52100 steel. AISI 52100 steel has been widely used in the bearing, mold, and automotive industries because of its superior wear resistance and mechanical properties. However, its high wear resistance caused poor machinability in conventional machining methods. Low surface quality, rapid tool wear, high cutting temperature, and high cutting force are the main difficulties in the conventional machining of AISI 52100 steel. On the other hand, ultrasonic-assisted machining has become widely used in the past decades for the machining of materials that have low machinability in conventional methods. Conventional turning and ultrasonic-assisted turning were selected as machining methods. Ultrasonic-assisted turning experiments were conducted under 20 and 30 kHz vibration frequencies. Cubic Boron Nitride (CBN) cutting tools were used in machining experiments. In machining operations 50, 100, and 150 m/min cutting speeds were selected, and feed rate (0.1 mm/rev) and depth of cut (0.5 mm) were kept constant in experiments. Minimum quantity lubrication technique which used 1% Al 2 O 3 nanoparticle additives cutting fluid and dry cooling methods were used. CBN insert was used as a cutting tool. The effects of cutting speed, cutting method, and cooling condition on surface quality, cutting force, cutting zone temperature, and cutting tool wear were studied experimentally. Analysis of Variance (ANOVA) was carried out to determine the significance of the effects of input variables on process outputs. As a result of this study, it is determined that combined UAT and nanoMQL have significant effects on the process outputs.
... Friction reduction, wear resistance, and extreme pressure performance are increasingly demanding [85]. The green development has become a topic of general discussion in the past years [86]. In addition, the water-based lubricants adapt to the theme of green development because of their low cost, good recyclability, and environmental protection [87]. ...
Black phosphorus (BP) is a new class of two-dimensional (2D) layered material, which shows the unanticipated characteristics in many aspects including electronics, transistors, sensors, energy storage, batteries, photocatalysis, and other applications due to its high charge carrier mobility, tunable direct bandgap, and unique in-plane anisotropic structure. In addition, BP has drawn tremendous attention in the field of tribology due to the low shear strength, the layered structure, and the weak connected force between the layers by van der Waals interaction. In recent years, many significant progresses have been made in experimental studies on BP materials as solid lubricants or lubrication additives. This work offers a review of researching regarding the tribological properties of BP. Moreover, the lubrication mechanisms of BP as the lubrication additive including the formation of the tribo-film, micro-bearing effect, and self-repair performance are also summarized. Finally, the current challenges and prospects of BP material as lubricant are proposed.
... In this sense, the exploration of biodegradable raw materials to be used as straight oils in MQL or in the production of green emulsions in MWFs has been the study topic of many worldwide research groups lately. It has been reflected in a huge amount of the literature reporting on the use and cutting performance of straight vegetable oils or synthetic esters as renewable and biodegradable bio-oils to replace mineral oils in MWFs for different machining applications, which has been recently (last five years) compiled in many comprehensive review articles [1,4,6,9,[14][15][16][17][18][19]. Those reviews addressed thorough analyses and discussions about state-of-the-art challenges and physicochemical, tribological and cutting performance properties of the most popular and promising bio-oils in MWFs. ...
This article presents a perspective on the potential use of microalgae oils in the production of metal working fluids (MWFs) used for minimum quantity lubrication (MQL) operations. The generalities of MQL operations and requirements of MWFs, and current advances in the development of the most promising microalgae oils with high contents of saturated, monounsaturated, and polyunsaturated fatty acids were reviewed and discussed. The analysis of data, discussions, and conclusions of numerous studies published recently and combined with the experience of the multidisciplinary team of authors strongly suggest that microalgae oils do indeed have great potential as sustainable and eco-friendly base oils for producing semi-synthetic MWFs, soluble oils and straight cutting fluids for MQL operations. Additionally, gaps and challenges focused on the use of agro-industry wastewater in microalgae production, green harvesting and oil extraction methods, and replacement of toxic additives in MWFs by green nanoparticles and biopolymers were identified and highlighted for achieving massive microalgae oil-based MWFs production and truly green machining processes.
... Beyond that, there is the bio-stability issue in vegetal-based fluids. By contrast, it is a good factor since it helps with disposal and provides a much faster environmental recovery [29]. On the other hand, biological attack and destabilization make it much more susceptible [30]. ...
... Challenges still exist in achieving sustainability through green manufacturing. A lack of research regarded to the addition of nanoparticles with different surfactants and additives has been reported (Katna et al., 2020). ...
Conventional metal working fluids are prepared from petroleum based mineral oils with toxic, carcinogenic, non-biodegradable and unsustainable additives, which can cause serious environmental contamination and health risks to operators. Formulations with non-toxic emulsifiers and natural additives such as vegetable oils are currently being considered for further development and use of non-toxic tribological products. This study is concerned with the thermal and flow properties of a cutting fluid (taladrine, T) mixed with a phase change material (PCM) coconut oil (CO) in a proportion of 1:9 (CO-0.1T) and hydrophilic silica in 0.01, 0.03 and 0.05 vol fractions. The thermal properties were evaluated by differential scanning calorimetry (DSC) and thermal conductivity measurements while the flow properties were assessed by viscosity temperature curves. The addition of solid particles has demonstrated an enhancement of the thermal conductivities with small differences in the latent heat. The microstructure of the suspensions was established from the DSC cooling dynamic thermogram and the rheological measurements. These results were confirmed by the images of optical polarized microscopy in which plate-like needles were observed. The suspension of 0.03 silica in CO-0.1T demonstrated an adequate gel strength and produced a reduction of 11 °C in drilling performance. A Minimum Quantity of Cutting Fluid (MQCF) of 2 g as an alternative for dry machining and flood cooling. It also prevented evaporative loss and removed metal chips, as a high viscosity complex fluid. In this work the use of phase change materials filled with solid particles as a way of sustainable eco-friendly toxic waste removal in drilling was justified.
... Rapeseed oil is one of the promising vegetal oils that could challenge the use of conventional lubricants, especially the mineral ones [1], [2]. The additivation of rapeseed oil should improve characteristics that are lower for the neat oil: viscosity, oxidation and tribological features [3], [4]. ...
The rapeseed oil is a promising eco-friendly lubricant for applications involving environment protection. But any vegetal oil has shortcuts especially related to low viscosity and thermal stability. Research in additivation with nanoparticles is of interest for improving load capability of the contact and for reducing wear. Other tribological characteristics, as friction coefficient, could oscillate around values offered by the neat vegetal oil, with more or less influence of the system behavior. The four-ball tester offer a reliable ranking of the tribological characteristics when comparing two or more lubricants. Usually, researchers used test parameters recommended in ISO 20623:2017 Petroleum and related products. Determination of the extreme-pressure and anti-wear properties of lubricants. Four-ball method (European conditions) and ASTM D2596:2020 Standard Test Method for Measurement of Extreme-Pressure Properties of Lubricating Grease (Four-Ball Method), implying 1500 rpm for 1 hour for normal regime. This study proposes to evaluate the tribological characteristics (friction coefficient, wear scar diameter � WSD and temperature during the tests) for five sliding velocities and three loads, taking into account the same sliding distance for each test. The additives were at nano scale and they were supplied by the company PlasmaChem: hexagonal Boron nitride (h-BN) with a particle size of 100-1000 nm, mean value 500 � 100 nm, and nano graphene as foils, with a thickness of 1.4 nm and particle size up to 2 ?m. The additivated lubricants were obtained by sonication.
... The spent cutting fluids that is been discharged on the ground in the figure below had spent eight months in the machine sump before final disposal. Long storage of cutting fluid in the machine sumps leads to nitrosamine [23]. Nitrosamines are carcinogens (cancer-causing agents). ...
This paper presents a report on cutting fluids utilization and its impacts on workers in machining workshops in Ibadan, Nigeria. The major users of cutting fluids and their workshops were identified. It was found that there are 103 operating metal workshops in Ibadan and these workshops are located within seven local government areas of the city. Out of the total number, 85 are in fabrication, 39 are in crankshaft operations and 32 are engaged in block boring operations. The type and consumption of cutting fluids, coolant delivery techniques, length of use before disposal, disposal methods, and monitoring maintenance were studied. The results indicated that the most used cutting fluid is soluble oil with average total consumption of 402 litres monthly. The pouring of spent cutting fluids on the ground is the most adopted disposal method. Research on occupation exposures to cutting fluids has suggested that machine operators in metal cutting are at high risk of developing cancer, allergenic disorders, and lung diseases. Results obtained also showed that less than 22% of machine operators were aware of occupational hazards. Few of the operators (23%) wore safety devices/clothing, and health and safety standards were neither practiced nor enforced.
... The usage of vegetable oil-based cutting fluids has been assessed for other lightweight alloys, such as titanium and aluminium alloys and offered promising results [25]. The use of vegetable oil-based cutting fluids can result in improved tool life, surface quality, and cutting forces in comparison to conventional dry and petroleum-based flood cooling techniques in a multitude of ferrous and nonferrous alloys [26,27]. ...
The implementation of magnesium alloys in a multitude of industries has been proven to be a mere effect of their attractive light weight, corrosion resistant, and biodegradable properties. These traits allow these materials to portray an excellent sustainable machinability. However, with increasing demand, it is essential to explore sustainable means of increasing production while mitigating reductions in sustainability. The current work aims to assess and optimize the high-speed machinability of AZ91 with the use of a vegetable oil-based minimum quantity lubrication (MQL) system using the grey relational analysis (GRA) on the basis of chip morphology and tool wear. The investigation entailed a full factorial design with MQL flow rate, cutting speed, and feed rate as the control parameters and flank wear, land width, chip contact length, saw-tooth pitch, chip segmentation ratio, chip compression ratio, and shear angle as the output responses. The optimal control parameters predicted and experimentally confirmed were an MQL flow rate of 40 mL/h, cutting speed of 300 m/min, and feed rate of 0.3 mm/rev. The usage of said optimal parameters results in a grey relational grade improvement of 0.2675 in comparison to the referenced first experimental run. Moreover, the MQL flow rate was regarded as the critical variable with a contribution percentage of 20% for the grey relational grade.
... A solution was found in the use of vegetable-based CFs, which are extracted from renewable sources, making them unlimited and sustainable [34]. Vegetable oils generally have several advantages over mineral-oil-based ones, such as reducing the health risks to operators by being less toxic, decreasing mist production leaving cleaner and healthier work environments, high-viscosity indices, higher lubricities, low evaporative losses and good metal adherence [17,35,36]. Unfortunately, these fluids also have some drawbacks, such as low thermal stability, low corrosion protection and poor oxidative stability [37]. ...
Improving machining performance and meeting the requirements of sustainable production at the same time represents a major challenge for the metalworking industry and scientific community. One approach to satisfying the above challenge is to apply different types of cutting fluids or to optimise their usage during the machining process. The fact that cutting fluids are well known as significant environmental pollutants in the metalworking industry has encouraged researchers to discover new environmentally friendly ways of cooling and lubricating in the machining process. Therefore, the main goal is to investigate the influence of different machining conditions on the efficiency of hard machining and find a sustainable solution towards smart manufacturing. In the experimental part of the work, the influence of various machining parameters and conditions on the efficiency of the process was investigated and measured through the surface roughness, tool wear and cutting force components. Statistical data processing was carried out, and predictive mathematical models were developed. An important achievement is the knowledge of the efficiency of compressed cold air cooling for hard milling with the resulting lowest average flank wear of 0.05 mm, average surface roughness of 0.28 µm, which corresponds to grinding procedure roughness classes of N4 and N5, and average tool durability increase of 26% compared to dry cutting and conventional use of cutting fluids. Becoming a smart machining system was assured via technological improvement achieved through the reliable prediction of tool wear obtained by radial basis neural networks modelling, with a relative prediction error of 3.97%.
... They conducted experiments and concluded that the cutting force was minimized by the vegetable oil-based cutting fluids and the surface finish was improved. The various types of vegetable oils proposed for diverse cutting processes can be found in [17][18][19]. Though a wide variety of vegetable oils were addressed by several researchers, there are many limitations including thermal and oxidation stability [4,5] which may be prevented by the addition of additives. ...
In spite of better performance, the disposal of used petroleum-based cutting fluids threatens our environment. Thus, it is essential to develop eco-friendly cutting fluids for performing machining operations in industries. The main contribution of this paper is to develop an eco-friendly cutting fluid for the plain turning of AISI 1010 steel which is used in the automotive industry. In the present work, boric acid (H3BO3) was mixed with the neem seed. Neem seed oil is easily available in many countries including India. The effectiveness of the proposed cutting fluid was evaluated by conducting different tests as per the standards. The mean biodegradability value of the developed cutting fluid is 97% which is better than other cutting fluids. The average cutting force required by the proposed cutting fluid is only 127.2 N which is much less than the cutting force requirements of dry machining and conventional cutting fluids. The average surface roughness of the machined component using the proposed cutting fluid is 122.9 µm. The mean flank wear of the tool is only 289 µm. The flash point of the proposed cutting fluids is more than 250 °C which is better than the conventional cutting fluids. The fire point of the neem oil-based cutting fluids is 300 °C. The results of the stability test and the microhardness test revealed the effectiveness of the proposed cutting fluids. The results obtained in this work are superior to several other cutting fluids reported in the existing literature. Hence, it is suggested to replace the existing petroleum-based metal cutting fluid with this eco-friendly cutting fluid in the automotive industry in Hosur, India.
... Recently, vegetable oil (VO)-based fluids have been suggested as favourable alternatives to conventional fluids owing to their superior tribological properties and high biodegradability [9]- [12]. Cutting fluid can be delivered into the machining zone using different cutting fluid supply systems, such as conventional flooding, high pressure cooling (HPC), Dr. Salah Gariani and Khaled Jegandi are Senior Researchers at the Libyan Authority for Research, Science and Technology, Training and Production Centre (TPC), Tripoli, Libya (phone: 00218913737083; e-mail: s.gariani@tpc.ly). ...
In this work, a cooling coherent round nozzle was developed and the impact of nozzle placement (i.e. nozzle angle and stand-off/impinging distance) on the machinability of Ti-6Al-4V was evaluated. Key process measures were cutting force, workpiece temperature, tool wear, burr formation and average surface roughness (Ra). Experimental results showed that nozzle position at a 15° angle in the feed direction and 45°/60° against feed direction assisted in minimising workpiece temperature. A stand-off distance of 55 and 75 mm is also necessary to control burr formation, workpiece temperature and Ra, but coherent nozzle orientation has no statistically significant impact on the mean values of cutting force and tool wear. It can be concluded that stand-off distance is more substantially significant than nozzle angles when step shoulder milling Ti-6Al- 4V using vegetable oil-based cutting fluid
... However, the cutting fluid could be absorbed by the moisture-sensitive composite [29] and long-term exposure to the coolant is detrimental to the physical, mechanical, and chemical properties of the composite [30]. Moreover, most cutting fluids contain toxic additives that are harmful to humans and the environment [31]. Also, when coolants are used, there will be additional time and cost involved in cleaning the machine parts [32]. ...
Carbon-fiber-reinforced epoxy composite (CEC) has gained widespread acceptance as a structural material in various applications. Drilled holes are essential for assembling composite material components. Reducing drilling-induced damage and temperature effects is crucial for improved surface quality and integrity of the drilled composite. In the present work, drilling experiments were conducted on CEC, hexagonal-boron nitride (h-BN) dispersed CEC, and molybdenum disulfide (MoS2) dispersed CEC at three different levels of spindle speed, feed, and drill diameter using solid carbide twist drills. The filler concentrations used in this study were 4, 6, and 8 wt%. Analysis of variance (ANOVA) was used to determine the significance of input factors (feed, spindle speed, drill diameter, and filler concentration) on the drilling responses such as thrust force, temperature, arithmetic mean surface roughness (Ra), and push-out delamination factor (DFexit). The average drilling temperature, Ra, and DFexit of MoS2 dispersed CEC were reduced by 24.7, 46.5, and 11.3%, respectively, when compared to neat CEC. In h-BN dispersed CEC, the average drilling temperature, Ra, and DFexit were reduced by 25.2, 40.9, and 13.2%, respectively, compared to neat CEC. The lubricating properties and high thermal conductivity of filler added to epoxy are responsible for the lower temperature and improved hole surface finish. The improved delamination resistance in filler-loaded CEC is due to the strengthening of the matrix and fiber–matrix interface. Scanning electron microscopy (SEM) was used to examine the morphology of the drilled composite surface. The spindle speed of 5500 rpm, feed of 0.03 mm.rev−1, and filler loading of 4 wt% produced the minimum Ra and DFexit. The response surface method (RSM) was applied to determine the input parameters based on multi-response optimum criteria.
... Beyond that, there is the bio-stability issue in vegetal-based fluids. By contrast, it is a good factor since it helps with disposal and provides a much faster environmental recovery [29]. On the other hand, biological attack and destabilization make it much more susceptible [30]. ...
The use of cutting fluids during machining processes remains one of the main challenges
toward greener manufacturing, mainly when applied by flooding. The use of vegetable-based cutting
fluids stands out as one of the alternatives toward more sustainability by making the process ecofriendlier
without much impact on the economic aspects of the chain. In this paper, the performance
of two vegetable-based cutting fluids applied by flooding was compared to one mineral-based during
the turning process of the AISI 1050 steel. They were also tested after aging for microbiological
contamination to assess the fluids’ sustainability further. The machinability of the cutting fluids
was evaluated by considering the tool life and wear mechanisms, workpiece surface roughness, and
cutting temperatures. After microbial contamination, all the fluids increased kinematic viscosity
and specific weight, except for the emulsion of vegetable-based fluid, where its kinematic viscosity
decreased. The vegetable-synthetic fluid obtained the best machining results in cutting temperature
and roughness (Ra) and also had the best behavior for microbial growth. However, considering the
tool life, the best result was obtained with the emulsion of the vegetable-based fluid.
Higher-end science and technology facilitate the human community with a sophisticated life despite it curses by abundant pollution. The alarming demand for sustainability pressurizes the manufacturing sector to ensure sustainable manufacturing. Since Molybdenum di sulfide (MoS2) and avocado oil are known solid and liquid lubricants respectively, hence, it is a worthwhile attempt to implement the bio-based degradable avocado oil enriched with nano Molybdenum di sulfide (nMoS2) particles as a potential machining fluid for CNC-end milling. Different proportions of avocado oil and nMoS2 were used to synthesise four distinct machining fluids to assess the individual impact of avocado oil and nMoS2 particles. The emulsification and sonication were employed to synthesise the fluids. A hybrid Grey Relational Analysis (GRA) coupled with Principal Component Analysis (PCA) was followed to scrutiny the effect of novel machining fluid on machining objectives. The experimental results of physio-chemical properties revealed that avocado-rich 0.5% nMoS2 excels among others. The L16 orthogonal array experiments associated with statistical analysis explored the developed machining fluid (A6W4/0.5) that significantly impacts the machining objectives. The experimental results manifest that nearly 64.87% of surface roughness and 93.3% of tool wear have been reduced during machining in the presence of A6W4/0.5 fluid than A4W6/0.75. The improved performance of the novel machining fluid upholds its potential to replace conventional fluids and ensure green manufacturing.
In order to improve the poor comprehensive performance of aluminum bronze surface, a duplex surface modification technology consisting of laser cladding and followed by plasma nitriding was adopted to prepare the infiltration composite modified layer. The effects of different surface treatment techniques on the microstructure and properties of the modified layer were investigated. The results show that the laser cladding surface is mainly composed of Cu-rich intermetallic compounds, and the AlN layer appears on the surface after plasma nitriding treatment, which significantly improves the hardness and tribological properties. The surface modification treatment changes the surface morphology. The microhardness of the alloy surface after composite modification is much higher than that of untreated and single treatment. It is about six times that of the Cu-Al matrix. At the same time, the composite modified layer has a lower friction coefficient and wear volume, showing excellent tribological properties. These research results can provide a new way for the surface design and development of metal materials.
This study evaluates the use of gingelly oil as an eco-friendly cutting fluid for the turning operation. Experiments were conducted to determine the effect of nose radius, and rake angle on tool wear, surface formation, and cutting force. In addition, different lubrication techniques, such as cutting fluids and bio-oils, were investigated to determine their potential for minimising friction, heat generation, and tool wear during machining. In comparison to dry cutting, and conventional petroleum-based lubricants, the results demonstrate that gingelly oil consistently produces smoother surface finishes, and reduces cutting forces. The relationships between cutting parameters, and surface finish were analysed using statistical modelling, with R-square and p-values used to quantify correlations and predictor significance. The findings highlight the viability of gingelly oil as a cutting fluid and the significance of optimising process parameters for increased machining efficiency.
In this experimental study, waste cooking oil is chosen as a sustainable coolant to remove the excess heat from metal removal operations. For this purpose, WCO is characterized for physicochemical, thermal, tribological, and rheological properties. In addition, the image processing (IP) technique is applied by capturing the WCO surface images to examine the possible reactions in WCO and changes on the metal surface when the oil interacts for 151 days. Around 135 surface images are captured to extract the significant red–green–blue (RGB) pixel information from the WCO. The possible changes in WCO are examined by studying their functional groups using Fourier transform infrared (FTIR) spectroscopy analysis. The results of thermal conductivity (0.191 W/(mK)), coefficient of friction (0.139 µ), frictional force (4.176 N), anti-wear (636.14 µm), and shear stress (0.09 Pa@60 °C) for WCO are observed lower than conventional metal-cutting fluid. Furthermore, IP results reveal no significant changes in RGB pixel intensity from the first day to the 151st day. In addition, the functional group analysis reveals no changes in the fingerprint and functional group region wavenumbers in the FTIR spectrum for first- and 151-day WCO samples. Therefore, it is concluded that WCO does not show any reactions with the metal, and it can be considered a sustainable bio-coolant for metal removal operations.
Conventional cutting fluids are widely employed globally as coolants and lubricants in grinding operations. However, these
fluids pose significant environmental and biological risks. To mitigate these adverse effects, a shift towards sustainable
machining techniques is imperative. Sustainable approaches involve minimal cutting fluid usage, cryogenic cooling,
utilization of vegetable oils, and the use of coated grinding wheels. The fluids employed in sustainable machining are
known for their complete biodegradability and eco-friendliness. This paper provides a comprehensive review of modern
sustainable techniques in metal-cutting processes. It reveals that these sustainable methods often yield superior results,
including enhanced surface quality, prolonged tool life, reduced cutting temperatures, and diminished cutting forces when
compared to conventional wet machining. The primary aim of this review is to identify and promote various sustainable
techniques in metal machining, fostering cost-effectiveness and environmental friendliness in the grinding process.
Metalworking fluids (MWFs) play a crucial role in machining processes by lubricating and cooling cutting tools, reducing friction, and improving overall machining efficiency. These fluids can be classified into various types, including cutting oils, water-based fluids, and semi-synthetic or synthetic fluids. Cutting oils are often mineral-based, providing excellent lubrication in heavy-duty applications. Water-based fluids, on the other hand, are more environmentally friendly and commonly used in light to moderate machining operations. Semi-synthetic and synthetic fluids offer a balance between performance and eco-friendliness, incorporating additives to enhance their properties. Proper selection and management of MWFs are essential for optimizing tool life, surface finish, and overall productivity in metal machining applications. Research has shown that the cost of cutting fluid in machining constitutes 17% of the total production cost. In the same research, it was stated that the cutting tool cost was around 4%. This review provides an overview of the current advancements in sustainable MWFs within machining applications. It explores state-of-the-art technologies, formulations, and practices aimed at minimizing environmental impact while maintaining optimal performance in metalworking processes. The review encompasses eco-friendly additives, recycling methods, and emerging trends in the development of MWFs, emphasizing the importance of sustainable practices in the manufacturing industry.
This paper explores the challenges of machining difficult-to-cut metals using tools like coated carbide, ceramics, and CBN under dry conditions, addressing issues such as heat generation, tool wear and friction, chip evacuation, surface integrity, vibration, and chatter. Though cutting fluids have historically improved machinability, environmental concerns, such as toxicity and non-biodegradability, are significant. Researchers aim to enhance the economic and ecological aspects of machining by reducing cutting fluid usage. This paper provides an overview of the performance assessment and sustainability evaluation of various cooling and lubrication methods during the machining of hard-to-machine as well as difficult-to-cut metals. Additionally, the literature review highlights various environmentally friendly cooling strategies, such as minimum quantity lubrication (MQL) and cryogenic arrangements. According to the results of this review, the utilization of various cooling and lubrication technologies has the potential to enhance both sustainability and machinability properties while prolonging the lifespan of cutting tools. The findings also show that there is a lot of room for improvement in terms of optimizing and making these cooling-lubrication solutions more practical and effective.
Electro-discharge machining (EDM) is preferred in aerospace, biomedical and automobile industries due to its ability to produce complex, intrinsic cavities with excellent surface finish. Ever-rising environmental restrictions, operator’s safety and improved life quality mandate the implementation of green manufacturing (GM). In this research, efforts are taken to accomplish the objectives of GM during EDM of Ti–6Al–4V by employing vegetable oil-based biodiesel dielectrics viz. Lemon peel, Karanja and Jatropha. The experiments are carried out with these dielectrics with different levels of current (10, 15 and 20 amps) and pulse on time (100, 150 and 200 µs). The impact of input variables and dielectric composition on tool wear rate (TWR), material removal rate (MRR) and surface roughness (SR) are studied. The workpiece average crater volume (WACV) and electrode average crater volume (EACV) are also calculated from the experimental data. The liberated emissions (LE) with conventional and different biodiesel dielectrics during the EDM operation (20 amps, 150 µs) are monitored and reported. A grey relational analysis (GRA) is performed to identify the desirable values for input parameters. At the optimized condition, about 72% increase in MRR and 17% drop in surface roughness are observed with the Lemon peel biodiesel over conventional EDM oil. Lower cost, less liberated harmful gases, better performance and sustainable nature of lemon peel biodiesel help in achieving GM objectives.
The conventional Metal cutting fluids (MCFs) used are mineral-based petroleum oils that perform well but are toxic and difficult to dispose of; therefore, these are hazardous to human health as well as the environment. This issue can be solved by using natural vegetable oil-based MCF, which are readily available, environment and human-friendly, and renewable. Therefore, we synthesized various types of emulsifiers (anionic, and nonionic with different ethylene oxide units as well as mono and gemini cationic surfactants as corrosion inhibitors and biocides) based on recycled vegetable oil (RO) from spent bleaching earth (SBE), and elucidated their chemical structures by different spectroscopic techniques. The individually synthesized emulsifiers (anionic, and nonionic with different ethylene oxide units) at different ratios (8–15 by wt.%) and mixed emulsifiers (anionic/nonionic, nonionic/nonionic with different degrees of ethylene oxide) at different ratios (8–12 by wt.%) were utilized as additives in the preparation of different vegetable residual oil-based MCF formulations. The mixed emulsifiers at different ratios of nonionic/nonionic with hydrophilic-lipophilic balance (HLB) value 10 (Formulas I, II, III, and IV), and anionic/nonionic (Formula V, and VI) exhibited stable emulsions compared to individual emulsifiers. Formulas (I and VI) displayed good protection effectiveness in corrosion tests. Formula VI had better wettability (25.22 on CS, 23.68 on Al, and 22.28 on WC) and a smaller particle size (63.97 nm). Tribological properties of Formula VI were also performed. The results exhibit that Formula VI is consistent with the commercial sample. As a result, this study contributed to the resolution of one of the industry's problems
Nano additive-based vegetable-oil fluids are playing a vital role in conventional thermal appli-cations due to their contribution to improved thermophysical properties. This work is focused on the synthesis and characterization of a novel ZnO-Ag hybrid nanoparticles-based sun-flower oil for thermal applications. Firstly, the ZnO-Ag hybrid nanoparticles were prepared by a wet chemical approach and characterized using SEM and TEM. The synthesized hybrid nanoparticles were then mixed in the sunflower oil to prepare various nanofluids at different volume concentrations ranging from 0.05 to 0.20%. The stability of the prepared nanofluids was investigated as a function of Zeta potential and visual examination. Further, the thermal conductivity and viscosity of prepared nanofluids were measured by the KD2-pro analyzer and Brookfield viscometer. The result showed that the thermal conductivity of prepared nano-fluids was increased up to 21.01% at 0.20% nanoparticles volume concentration. Finally, an artificial neural network model was developed to accurately predict the thermal conductivity of prepared nanofluids.
Chemicals of concern may emerge in our environment in many ways. Two distinct ways are through the design of the compound or by molecules/functionalities added to the original compound. In this chapter, we will use ionic liquids (ILs) and halloysite nanotubes (HNTs) to illustrate these two ways. ILs are salts that are typically composed of organic cations and inorganic anions. While they were initially promoted as “green” solvents, this characterization is not necessarily true. The potential number and uses for ILs seem almost limitless. HNTs are a form of naturally occurring clay, possessing mostly a nanotubular structure and a similar chemical composition to kaolin. The tubular morphology and the aluminum silicate structure of HNTs have allowed them extensive use in science, engineering, and medicine. The growth of the biorefinery and green chemistry, circular chemistry, and sustainability will provide increasing access of these compounds into the environment. This extended use of both ILs and HNTs increases their presence in the environment. While the ILs which may be toxic depending upon their composition, HNTs may become toxic due to what is loaded in/on them. While the utility of these chemicals is unquestionable, understanding their environmental behavior, fate, and effects is critical.
The difficulties in machinability due to the developments in the technical properties of engineering materials increase the importance of machinability indicators such as surface quality, power or energy consumption and tool life in terms of sustainable machining. In this context, the machinability of a copper-beryllium alloy (C17500), which is used in a wide range of industries and also characterized as a hybrid material, was investigated in vortex tube cooling and dry cutting environments. First, turning experiments were performed with a coated carbide tool and varying cutting speed, feed rate and depth of cut. In the experiments, the total energy consumed during turning and the roughness of the machined surfaces were measured, and analysed experimentally and statistically. In the second stage, mathematical models were developed for the total energy consumption and average surface roughness for both cutting environments with the response surface method. As a result, the chip formation process in the turning of the Cu alloy under vortex tube cooling negatively affected the cutting power and positively contributed to the surface quality. Due to the fact that vortex tube cooling creates a cooling effect rather than lubrication, built-up layer/built-up edge (BUL/BUE) formation on the tool cutting edges caused the change in the tool geometry and thus the chip removal process became more difficult and increased the energy consumption. On the other hand, in the vortex tube cooling application, the surface roughness decreased by an average of 31.4% compared to dry cutting. Furthermore, the predictive mathematical models developed for the total energy consumption and the mean surface roughness can be used with high reliability.
Çevre sorunlarına ilişkin sürekli artan kamu bilincine paralel olarak daha yeşil bir dünya arzusu, toplumları çevre dostu ürünler kullanmaya yöneltmiştir. Sürdürülebilirlik, enerji verimliliği, atıkların geri dönüşümü ve maliyeti gibi kavramların her geçen gün gelişen teknoloji ile birlikte daha çok ön plana çıkmasıyla biyo-kökenli ürünler vazgeçilmez duruma gelmektedir. Çevreye zararlı maddeler içeren ve atıkları kolayca bertaraf edilemeyen petrol türevi ürünlerin yerine, çevre dostu, zehirsiz, doğada kısa sürede kolayca bozunabilen, yenilenebilir kaynaklardan bitkisel yağlar ve türevi ürünler iyi bir alternatif oluşturmaktadırlar. Çok yönlü kullanım alanına sahip olan bitkisel yağlar, birer besin maddesi olmalarının yanında kimya ve enerji sektörü başta olmak üzere endüstride önemli bir hammadde kaynağı oluşturmaktadırlar. Biyodizel yakıt, endüstriyel yağlayıcı, mürekkep, kozmetik, ilaç, boya ve vernik üretimleri başta olmak üzere, plastik, deterjan, şampuan, dezenfektan, sabun, tutkal, aydınlatma ve cam macunu gibi çeşitli sanayii ürünlerinde hammadde olarak kullanılmaktadır. Endüstrinin ihtiyacı olan bitkisel yağlar genel olarak, soya, ayçiçeği, çiğit (pamuk tohumu), kanola, kolza, yer fıstığı, susam, pelemir, aspir, krembi, hintyağı, haşhaş, keten, kenevir, mısır (mısır özünden), zeytin, hurma (palm), hindistan cevizi (coco) ve jojoba bitkilerinin yağlı tohumlarından elde edilir. Genel olarak yemeklik olarak da kullanılan bu yağların yanı sıra neem yağı, karanja yağı, jatropha yağı gibi gıda sektöründe kullanılmayan yenmeyen yağların endüstride uygulanabilirliği konusunda yapılacak araştırmalar bitkisel yağların etkinliğini daha da artıracaktır. Yenmeyen bitkisel yağların endüstride kullanımı, sürdürülebilir üretim açısından daha iyi bir alternatif oluşturacaktır.
Kesme sıvıları, metal kesme ve işleme endüstrisinin en temel ve önemli bir parçasıdır. İmalat endüstrisinde, metal işleme veya metal kesme sıvıları, hem soğutucu hem de yağlayıcı olarak kullanılır. Tornalama, frezeleme, delme, taşlama, azdırma, kılavuz çekme, tığ çekme vb talaşlı imalat işlemleri, ürünlere nihai şeklini vermek için endüstride kullanılan en yaygın üretim süreçlerindendirler. Talaşlı imalatta, iyi yüzey kalitesi ve uzun takım ömrü sağlamasından dolayı kesme sıvılarının kullanılması tercih sebebidir. Genel olarak imalat endüstrisinde; saf-düz yağların yanında çözünebilen yağlar (bor yağı vb emülsiyonlar), sentetik sıvılar ve yarı sentetik sıvılar gibi su esaslı konvansiyonel kesme sıvıları soğutma yağlama amacı ile kullanılmaktadır. Ancak kullanılan bu petrol esaslı konvansiyonel kesme sıvıları, yüksek derecede toksik ve biyolojik olarak parçalanamazlar. Bu yüzden, çevre ve çalışan sağlığı üzerinde ciddi olumsuz etkileri vardır. Bu durum, şirketlere yüklediği yasal yükümlülüklerin yanında depolama ve elden çıkarma masraflarından dolayı toplam maliyetin artmasına neden olmaktadır. İmalat işlemlerinde sürdürülebilir üretim uygulamalarına olan talepten dolayı sağlığa zararsız, çevre dostu kesme sıvılarının araştırılması ve geliştirilmesi, araştırmacılar ve imalat mühendisleri açısından çok önemli bir konudur. Bu noktada, metal kesme ve işleme işlemleri için kesme sıvısı olarak kullanılabilecek, biyolojik olarak parçalanabilirliği yüksek ve daha az toksik bitkisel yağ esaslı kesme sıvıları ön plana çıkmaktadır. Çünkü bitkisel yağ esaslı kesme sıvılarının, çevresel etki, çalışan sağlığı, atık yönetimi gibi imalat operasyonlarının sürdürülebilirliğini belirleyen birçok konuya çözüm getirmesi muhtemeldir. Çevre dostu bitkisel yağ esaslı kesme sıvıları, özellikle talaşlı imalat süreçlerindeki deneysel araştırmalar sonucunda elde edilen performans gelişmeleri ile son yıllarda büyük ilgi görmeye başlamıştır.
Nickel based alloys are found in industrial sectors of aerospace and gas turbines. The present study focused on the hBN nanofluid's impact on six different superalloys machinability aspects with TiAlN coated carbide tool. Further, the input-parameters optimization is through the CRITIC-WASPAS methodology. The experiments are performed by considering the workpiece, nanofluid weight concentration, speed, and feed rate based on an L18 mixed-level orthogonal design. The nickel-based samples are Nimonic 75, Inconel X-750, Nimonic C-263, Nimonic 90, Hastelloy X, and Inconel 625. The impact of nanofluids on various superalloys on the force, roughness, and residual stress are measured and analyzed. The results show that the lowest cutting force is for Inconel 625, the highest surface finish for Inconel X-750, and the lowest tensile residual stress for Nimonic 75 at the determined optimal levels of 1.00% wt. of hBN, 70m/min, and 0.14mm/rev. The highest tensile residual stress is found for Inconel 625 (779MPa) and the lowest for Nimonic 75 (673MPa). The highest roughness value is 1.294µm for Inconel X-750, while the lowest is 0.752µm and 0.780µm for both Inconel 625 and Nimonic 90. The highest cutting force of 368N is experienced for Nimonic C-263 and the least of 217N for Inconel 625.
Cutting fluid is indispensable in the machining industry as a fluid for lubrication and cooling in the metalworking process due to their ability to significantly improve various properties of cutting fluid. Castor oil, as a common base oil and additive in cutting fluid, can be grafted onto the surface of cellulose nanocrystals (CNC) to further enhance the lubricating properties of cutting fluid. It has been shown that cellulose nanocrystals and castor oil modified cellulose nanocrystals (CO-CNC) as additives in cutting fluid have good dispersion stability and can effectively improve the lubricating properties. When the amount of CNC or CO-CNC was added in the working fluid at about 0.5 wt%, the friction coefficient was significantly reduced. According to the results from this study, cellulose nanocrystal is a promising candidate as the nontoxic and renewable additive for the improvement of diverse performances for the water-based cutting fluid.
This review presents the literature review on the recent research on the tribological performance of non-water miscible lubricants. First, the paper reviewed the tribological properties of vegetable oil, blend oil, synthetic oil and ionic liquid. Aside from that, the tribological performance of lubricants with ionic liquids (ILs) and nanoparticles is being studied. According to the findings, more research should be conducted into oil-miscible ILs for mineral, vegetable oils and nanolubricant. The review has also explained the dispersion stability, viscosity and viscosity index, thermal conductivity, thermal-oxidative stability and tribological performance of nanolubricant. Finally, future recommendations on lubricant research are also discussed.
Metal cutting fluids (MCFs) have played a principal role as coolants and lubricants in the machining industry. However, the wide use of mineral-based oil MCFs has contributed to an adverse effect on humans and the environment. Thus, to overcome the adverse effects of mineral-based oil MCFs, eco-friendly vegetable oil, which is non-edible oil, has been implemented to overcome the issues related to edible oil such as manufacturing costs and food shortages. This study investigated the performance of three different types of non-edible oil, namely castor, neem, and rice bran oils in drilling Inconel 718 using a coated titanium aluminum nitride (TiAlN) carbide drill towards tool life, tool wear, surface integrity, dimensional accuracy, and chip thickness. The MCFs were implemented under the minimum quantity lubrication (MQL) condition at a 50 mL/h flow rate using different cutting speeds (10, 20 m/min) and a constant feed (0.015 mm/rev). The results showed that castor oil minimizes the rapid growth of tool wear and prolongs the tool life by 50% at 10 m/min as compared to rice bran oil. At 20 m/min, castor oil obtained the lowest values of average surface roughness (1.455 µm) and chip thickness (0.220 mm). It was also found that different cutting speeds did not contribute to any significant trend towards hole diameter and roundness for all MCFs. The outstanding performance of castor oil proved that the oil is a potential alternative as an eco-friendly MCF for a cleaner machining environment. Castor oil was determined to be optimum in terms of tool life, tool wear, surface roughness, and chip thickness.
Minimum quantity lubricant milling (MLQM) with nanofluids is one of the main processing methods used in sustainable green manufacturing. Nanoparticles can drastically enhance the heat transfer ability of metalworking fluids. Thus, nanofluids modified with different nanoparticles have important applications as milling coolants. Nevertheless, few studies have investigated the influence of different nanoparticles on the cooling mechanisms of nanofluids. An experimental study was conducted to explore the cooling performances of different nanofluids in the MQLM of Ti–6Al–4V. Cottonseed oil was used as the nanofluid base and was modified with six different nanoparticles at the mass ratio of 1.5%. Cooling performance was evaluated with several milling parameters, including milling force, instantaneous temperature, and surface roughness, which was represented as the arithmetic average height (Ra) of the workpiece surface. The microtopography of the final milled samples was also examined. Results demonstrated that the mean of the milling force peak in the X direction under milling with SiO2 nanofluid was 436 N, which was lower than that under milling with MoS2 nanofluid (445.5 N). The lowest milling temperature was obtained with SiO2 nanofluid. This result indicated that SiO2 nanoparticles had the strongest cooling capacity. Workpiece temperature rapidly decreased to a low value under milling with SiO2 and Al2O3 nanofluids. The most drastic temperature drop was observed in MQLM with SiO2 nanofluid, followed by that in MQLM with Al2O3 nanofluid. The lowest Ra value was obtained under milling with Al2O3 nanofluid (0.59 μm), followed by that obtained under milling with SiO2 nanofluid (0.61 μm). The Ra value acquired under milling with Al2O3 nanofluid was 66.7% lower than that of acquired under milling with pure cottonseed oil. Given that Al2O3 and SiO2 nanoparticles demonstrated the best cooling performance, they are highly suitable as additives for the base oil.
Environment degradation and non-biodegradability are the major problems associated with mineral-oil based lubricants. Non-edible vegetable oils are one of the suitable substitutes for the mineral oils. In this study, pongamia oil was used as the lubricant to check its feasibility for the tribological behaviour. TiO2 nanoparticles are added to the pongamia oil on a weight-percentage basis. The variation of TiO2 nanoparticles concentration with pongamia oil was evaluated for the coefficient of friction and wear analysis. Minimum coefficient of friction and wear was observed at 0.1 % concentration which gets further increased at 0.2 % concentration. The smooth surface of the pin was observed at 0.1 % nanoparticles concentration with the comparison to base pongamia oil.
Mineral oil and sulfonates have been the basic source of cutting fluid formulations, but their uses have been questioned nowadays as regards to cost, health and environmental issues. The use of vegetable based cutting fluids is increasing and minerals based cutting fluids are likely to be replaced with vegetable based cutting fluids. The present study assessed the lubricity of blended oil from Castor and Neem seeds. These oils were extracted by mechanical method. The blends were formulated by varying the amount of each oil in the blend to see its effect in the properties and characteristics of the oil. The oil obtained was investigated for physicochemical parameters and fatty acid profiles. The fatty acid in Neem oil showed the presence of oleic acid (41.9%), linoleoic acid (19.50%), stearic acid (18.68%), palmitic acid (15.56%) linolenic acid among others, while that of Castor oil had palmitic (0.46%), Stearic (0.72%), Linoleic (4.4%), Linolenic (0.2%), Dihydroxylstearic acid (0.69%) and ricinoleic acid (90.58%). Lubricity of the formulated cutting fluid was tested using four balls tribo meter tester and the results obtained showed minimum Wear Scar Diameter of 0.13 mm which is the least among the formulated oils obtained in the 60% Neem and 40% Castor oil; this implies that this formulation has maximum lubricity in terms of friction reduction as compared to other formulated oil and the conventional soluble oil available in the market. This combination was found to be the optimum sample compared to other blends.-129 The formulated cutting fluids were further tested in machining mild steel. The chip thickness formed using the formulated cutting fluid at 90rpm was found to be 0.203 mm which is higher than that of the conventional cutting fluid obtained as 0.17 mm at constant depth of 2 mm; the high chip thickness value is due to its better lubricity property which allows for better metal removal rate, good surface finish and continuous chip formation.
The use of cutting fluids in machining processes is a serious concern because their cost, and environmental and health effects. In the last decades, efforts have been developed to come up with alternatives to overcome their main drawbacks. The ultimate goal is the complete suppression of cutting fluids. However, because of the demanding requirements of the machining processes, in some cases it is not possible to use dry machining conditions. Reasons can be found in the excessive heat generated in the process, the increase of the friction between the tool and the workpiece or the need to evacuate the chips generated. The pull for sustainable products is also encouraging the developing of new cutting fluid formulations. In the present paper, a comprehensive analysis of the use of cutting fluids and main alternatives in machining is carried out. Particularly, the analysis was done focusing on the economic, environmental and technical points.
Addressing the problem of high chemical oxygen demands (COD) of cutting fluid waste generated in the machining process, its complex composition, and the specific conditions required for the treatment process, a heterogeneous Fenton fibre catalyst (NZVI@ACF) made of nanometer-iron supported on activated carbon fiber using dip-molding was developed. NZVI was homogeneously loaded onto ACF surfaces to form NZVI@ACF, with a specific surface area (SBET) of 726.3642 m2/g. Using a multistage chemical pretreatment, the NZVI@ACF/H2O2 system was used to effectively treat cutting fluid waste. The results indicated that the rate of COD removal in the cutting fluid waste liquid pretreated with NZVI@ACF/H2O2 system was 99.8% when the reactions conditions were optimized to 20 nmol/L H2O2, 6 g/L NZVI@ACF, total reaction time of 120 min and pH 5. The treated waste solution passed China's tertiary wastewater discharge standards. NZVI@ACF/H2O2 demonstrated an excellent catalytic performance compared to the traditional Fenton catalyst, increased the effective pH reaction range and had an adsorption effect on the waste liquid after the reaction.
Owing to the desirable properties of vegetable oils as cutting fluids, an attempt is made to explore the potentiality of plentifully available vegetable oils as a cutting fluid for turning AA 6061. Two nonedible vegetable oils, Jatropha and Pongamia, in their chemically modified (epoxidized) versions are used as straight cutting fluids. Cutting fluids are introduced to the machining zone with the aid of Minimal Quantity Lubrication (MQL) method. Taguchi’s technique of orthogonal arrays is used to develop an effective design of experiments. The results obtained under epoxidized versions of Jatropha and Pongamia oils are compared with the results of mineral oil in terms of cutting forces and surface roughness. Experimental observations and statistical analysis show that, compared to mineral oil, the modified versions of vegetable oil-based cutting fluids are more effective in reducing the cutting forces and increasing surface finish. It is also observed that the modified Pongamia oil showed lesser flank wear compared to the other two tested oils.
The use of metal working fluids widespread with the industrial revolution in the late century. Petroleum based cutting fluid were being extensively used in the machining area causing health and ecological-related issues. The present work tried to elaborate the performance of eco-friendly and user-friendly karanja oil in water based cutting fluid during orthogonal cutting of AISI 1045 steel. Further attempt has been made to identify influence of developed and conventional cutting fluid on chip formation. Based on the findings of the study, a great reduction of 11% was observed in chips thickness which significantly increases tool life.
Machining with conventional flood lubrication system is a general practice in the manufacturing industries for reducing friction, heat and cutting power. The type of cutting fluid used during machining play important role in enhancing the machining performance if and only if it is selected, applied, handled and disposed in proper way. The research aimed to evaluate the performance of aloe vera oil as a cutting fluid in machining of M2 Steel, carbide cutting tool insert was used as a cutting tool under different machining parameters with different types of cutting fluids such as aloe vera oil and conventional cutting fluid in machining. The performance of developed cutting fluid is compared with conventional cutting fluid. The results of surface roughness obtained during Turning of M2 Steel with Minimum quantity lubrication of both mineral oil and vegetable are compared with each other and it is observed that the surface roughness of non edible vegetable oil i.e. alove vera give better surface finish compared with mineral oil also improved performance in terms of tool wear found while comparing alove vera oil with conventional cutting fluid.
In this review paper we introduce at first the cage nature of diamondoid molecules, the variety of their crystalline lattice structures, the nature of their structural isomers, their stereoisomers, and their other molecular specificities. The natural occurrence of diamondoids in petroleum fluids and how they come to be present in such fluids is introduced. Field experiences of phase transitions and depositions as well as techniques for separation, detection and measurement of diamondoids from petroleum fluids is presented and discussed. It is demonstrated that due to their six or more linking groups diamondoids have found major applications as templates and as molecular building blocks in polymers synthesis, nanotechnology, drug delivery, drug targeting, DNA directed assembly, DNA-amino acid nanostructure formation and in host-guest chemistry.
Exploration of 209 available Material safety data sheets of 85 straight oils, 46 emulsions, 51 semi-synthetics and 27 synthetics was carried out to provide a report on the most widely used components defined as dangerous substances. As many as 217 of different substances of which 15 were identified as biocides, 17 as corrosion inhibitors or neutralizing agent, 17 were lubricity improvers and 38 different base fluids, lubricity solvents or surfactants, while 93 substances were not identified specifically and 37 substances occurred only once. This article is focused on the list of base fluids in straight oils and their possible health effects.
The Petroleum derived cutting fluids are used across the world. It causes the environmental pollution viz. water contamination, air and soil pollution due to low biodegradability and also affects the health adversely. Vegetable based cutting fluids are less toxic, high biodegradability and environmental friendly. The objective of work is to introduce Karanja oil in water based cutting fluid in turning operation using EN8 steel. Further attempt has been made to identify the influence of karanja oil in water based cutting fluid on thrust force, feed force, radial force. The performance of developed cutting fluid is also compared conventional cutting fluid. The result shows that karanja oil in water based cutting fluid lower thrust force and radial force by 21% and 15% respectively. There is no improvement observed in feed force when using developed cutting fluid.
Cutting fluids are used in machining industries for improving tool life, reducing work piece and thermal deformation, improving surface finish and flushing away chips from the cutting zone. Although the application of cutting fluids increases the tool life and Machining efficiency, but it has many major problems related to environmental impacts and health hazards along with recycling & disposal. These problems gave provision for the introduction of mineral, vegetable and animal oils. These oils play an important role in improving various machining properties, including corrosion protection, lubricity, antibacterial protection, even emulsibility and chemical stability. Compared to mineral oils, vegetable oils in general possess high viscosity index, high flash point, high lubricity and low evaporative losses. Vegetable oils can be edible or non-edible oils and Various researchers have proved that edible vegetable oils viz., palm oil, coconut oil, canola oil, soya bean oil can be effectively used as eco-friendly cutting fluid in machining operations. But in present situations harnessing edible oils for lubricants formation restricts the use due to increased demands of growing population worldwide and availability. In the present work, Non-edible vegetable oil like Neem and Honge are been used as cutting fluid for drilling of Mild steel and its effect on cutting temperature, hardness and surface roughness are been investigated. Results obtained are compared with SAE 20W40 (petroleum based cutting fluid)and dry cutting condition.
Shear angle and sticking length are two crucial parameters in mechanics of metal cutting. These two parameters directly influence machinability factors such as cutting forces. Thus, shear angle and sticking length were investigated in vibratory turning process by using a pneumatic quick-stop device which was designed and fabricated, in this study. After preparation of ultrasonic assisted turning set-up, experimental tests have been carried out on two types of steel: AISI-1060 and AISI 304. Accordingly, the process of chip formation in each particular cutting test was quickly stopped when deformed chip was still in contact with workpiece. As a result, it was revealed that added linear vibration leads the turning operation to be improved by increase of shear angle and decrease of sticking length. Moreover, the effect of ultrasonic vibration on cutting force and chip micro-hardness is evaluated.
The tribological properties of di(2-ethylhexyl)phosphate-di(2-ethylhexyl)ammonium ionic liquid (DOPD) and 2-(4-dodecylphenyl)-6-octadecyl-1,3,6,2-dioxazaborate (DBDB) as lubricant additives in rapeseed oil (RSO) were investigated. The results indicate that DBDB and DOPD have outstanding synergistic effects on extreme pressure, friction-reducing and antiwear properties and the synergistic effects are enhanced with the increase of applied load. SEM-EDS and XPS analysis results reveal that the outstanding synergistic effects between DBDB and DOPD originate from the good collaboration of the triboreaction products generated from DBDB and DOPD to form a stable and compact tribofilm with low shearing strength, which is composed of B 2 O 3 , BN, phosphates and/or polyphosphates, organic amine and organic and/or inorganic ammonium, as well as Fe 2 O 3 .
Friction between work piece-cutting tool-chip generates heat in the machining zone. The heat generated reduces the tool life, increases surface roughness and decreases the dimensional sensitiveness of work material. This can be overcome by using cutting fluids during machining. They are used to provide lubrication and cooling effects between cutting tool and work piece and cutting tool and chip during machining operation. As a result, important benefits would be achieved such longer tool life, easy chip flow and higher machining quality in the machining processes. Non-edible vegetable oils have received considerable research attention in the last decades owing to their remarkable improved tribological characteristics and due to increasing attention to environmental issues, have driven the lubricant industry toward eco friendly products from renewable sources. In the present work, different non-edible vegetable oils are used as cutting fluid during drilling of Mild steel work piece. Non-edible vegetable oils, used are Karanja oil (Honge), Neem oil and blend of these two oils. The effect of these cutting fluids on chip formation, surface roughness and cutting force are investigated and the results obtained are compared with results obtained with petroleum based cutting fluids and dry conditions.
In the last many decades, the usage of cutting fluid is a common technique for improving the machinability of metals. The application of cutting fluid during the machining phase significantly influences the environmental burden of the process. The disposal of these cutting fluids imposes threat to the environment due to their high noxiousness and non-biodegradable. Several researchers in the metal cutting sector have focused their work to improve the economic and ecological conditions of the machining process by reducing the consumption of the cutting fluids. There is a need to explore different green and innovative techniques to facilitate cooling and lubrication during the machining phase. The conventional cutting fluids not only have environmental and health restrictions, but also they are costly due to the strict regulations for disposal. In this paper, sustainable nature of different cutting fluids has been investigated. The paper also provides a detailed review of the cooling strategies with respect to their environmental impact on human’s health and developments in eradicating the usage of conventional cutting fluids has also been reviewed. Furthermore, different environment friendly cooling strategies, mainly minimum quantity of lubrication (MQL), and cryogenic arrangement have been reviewed in the literature, and it is found that there is a giant scope of further research work to optimize these cooling strategies in order to make them functionally applicable.
Hot metal manufacturing process involves high temperature tribology. A class of high temperature lubricants of inorganic polymers will be developed for hot metalworking operations. Borax-, silicate- and polyphosphate-additives are polymeric in nature that deliver the appropriate friction and wear properties, their emergence will help to minimize materials loss, ensure control and stability of the hot metalworking process, and meet ever-increasing demands for surface quality, from the perspective of tribology at an industrial scale. Polyphosphate salt will be a cost effective lubricant that can adapt to a wide range of temperatures, while borate can impart very stable friction at the mating surfaces and silicate additives embodies excellent restoration at rubbing surface toward less friction. This overview includes much data mainly from the testing at ambient temperature, and more scientific evidence is tried to find to support their effective function at elevated temperature. Some challenges and the potential breakthrough are further highlighted in high temperature tribology applications.
The limited resources of petroleum-based lubricants and increased environmental contamination, that they produce, lead to increased demand for bio-lubricants. Due to several factors such as biodegradability, good lubricating properties and low production costs, the plant oils represent a good alternative as reference to replace the petroleum-based oils. Obviously, the need to ensure the use of vegetable oils as a source of food makes non-edible vegetable oils a formidable source for plant oil lubricants. Thus, the toxicity of Jatropha Curcas L. oil makes it a very attractive and alternative lubricant source. Therefore, the aim of this work is to investigate on tribological performance of Jatropha Curcas L. oil in the lubricating contact pair AISI 52100 steel sliding against X210Cr12 steel. The experimental tests were carried out using ball-on-flat reciprocatory tribometer for several frequencies and with normal load of 12N. The Jatropha Curcas L. oil was analyzed for its chemical and physical properties such as viscosity, density and flash point. The results were interpreted on the basis of the evolution of the friction coefficient. The evolution of the friction coefficient was monitored for 40 min in all tests. The results show that the friction coefficient decreases with the increase of the frequency, and the final value stays in the range of 0.04-0.122.
Metalworking fluid (MWF) is commonly used to reduce wear and friction, thus improve the machining productivity and quality. However, the usage of conventional MWF made from mineral oil causes negative effects to the ecology and human health. Therefore, it is desirable to formulate a sustainable MWFs as an alternative to petroleum-based oils. The crude jatropha oil was chemically altered via transesterification process of jatropha methyl ester and trimethylolpropane to develop various compositions of modified jatropha oils (MJOs). The orthogonal cutting process was carried out and the lubricants were supplied by using minimum quantity lubrication (MQL) technique. It was observed that the MJO5 exhibits an outstanding performance in terms of wear and friction as well as cutting force and maximum cutting temperature when compared to commercial synthetic ester (SE). This works shows that MJO5 is a viable candidate to replace SE as a machining lubricant.
The search for more sustainable products has been motivating the metal-mechanic sector to replace its mineral-based lubricants with renewable products. The great demand for products that make minor environmental impacts have pointed to the vegetable oils as an alternative due to its lubricating power. This study aims to explore the potential use of oils from Jatropha curcas and Moringaceae for machining processes. For this purpose, physical-chemical, tribological and machining analyses using vegetable oils were compared with products commercially used in the manufacturing industry. The tribological tests with vegetable oils from Jatropha and Moringa showed reduced worn area compared with emulsifiable and integral commercial oils. Despite the pure vegetable oil showed good lubrication capacity, for a machining process of aluminum alloys the cooling function is also wanted. The Jatropha-based coolant has provided a better machining performance for both cutting conditions, one with low cut feed rate another with high cut feed rate, than those of Jatropha-based ester, Canola-based, and mineral-based coolants. The vegetable-based metalworking fluids showed to be technically viable and environmental-friendly, as they are less toxic and derive from renewable and biodegradable resources.
Metalworking is a major industry in the United States today. Metalworking operations include rolling, forging, stamping, drawing, forming, cutting, and grinding. Practically all metal objects, from structural steel beams to screws, have undergone at least one metalworking operation.
Thermo-mechanical loads are the main factor that influences the tool wear and product surfaces during machining processes. Lubrication in metal cutting is an effective medium to reduce frictional forces and wear on the tool-workpiece interfaces. On this regards, the advantages of using refined bio-based metalworking fluids (MWFs) with the presence of low toxic, biocompatible and oil-miscible ionic liquids (ILs) additives ([N1,8,8,8 ][NTf2 ] (AIL) & [P6,6,6,14 ][(iC8)2PO2 ] (PIL)) at nominal weight concentrations of 1, 5 and 10% are explored during orthogonal cutting of AISI 1045 steel. Accordingly, the lubricants are supplied via minimum quantity lubrication (MQL) technique and comparative studies are conducted against the performance of the neat modified Jatropha-based lubricant (MJO) and commercially available synthetic ester-based MQL cutting fluid (SE). The combination of mist supply of the MJOs during machining have a great impact on cleaner production that eliminates the excessive usage of fluids and supports the utilization of environmentally friendly chemicals. This work extends the application of a minute quantity of fully miscible ILs in polar vegetable-based MWF which proven to provide a significant improvement on the lubrication effect of the MJO. MJO+AIL10% and MJO+PIL1% showed the best cutting performance amongst all lubricant mixtures with reduction of cutting forces and specific cutting energy by 4 to 5%, cutting temperatures by 7 to 10%, friction coefficient by 2 to 3%, tool-chip contact length by 8 to 11%, chip thickness by 22 to 25%, friction angle by 1 to 2% and increased shear angle by 25 to 29% compared to the SE. Besides, the effect of low friction and reduced cutting forces produced lower specific cutting energy that promotes "greener" and more sustainable working environment.
Knowledge of the performance of vegetable oil based cutting fluids, speed, feed, depth of cut in machining of different work materials is of critical importance in order to improve the efficiency of any machining process. The efficiency can be evaluated on certain process parameters such as Surface Roughness & Power Consumption. The objective of this work is to determine optimal parameters of cutting 904L stainless steel for dry and wet conditions. L27 Orthogonal array was used for the experimentation & Analysis was done by using ANOVA. In this work the Performance of the two vegetable oil based cutting fluids like Soyabean oil & castor oil was observed. It was found that Soyabean oil performs better than Castor oil in reducing Surface roughness. The results found that the feed rate is highly control parameter, which influence the surface roughness parameter in machining of 904L steel. In ANOVA it was found that depth of cut has greater influence on Power Consumption.
Cutting fluids are essential for cutting performance and rust prevention in metalworking processes. Among cutting oils, the usage of water-soluble cutting fluids is increasing rapidly because they afford excellent cooling performance and ensure fire safety. However, water-soluble cutting fluids also offer a favorable environment for the growth of a wide variety of microorganisms. The growth of microorganisms can lead to various problems such as deterioration of the cutting fluids and odor generation. Thus, technologies for purifying the waste of water-soluble cutting fluids are required. In this study, we developed an ozone treatment technology that uses an air DBD plasma system. Furthermore, sterilization experiments were performed with K. pneumoniae, P. aeruginosa, E. coli, and P. vulgaris as representative microorganisms. The system offers the advantages of low power consumption and simple structure. Approximately 1000 ppm of ozone could be stably generated under optimized conditions, and the ozone was injected into the reactor as micro-bubbles for improving reactivity and inactivation rate. The sterilization experiments confirmed that the water-soluble cutting fluid was sterilized by 99.99%. As a result, the turbidity, pH, and odor of water-soluble cutting fluid have been improved.
This paper studies the applications of modified Jatropha oil-based (MJO) lubricant as potential vegetable-based metalworking fluids, containing additives of two oil-miscible ionic liquids; [P66614][Phosphinate] (PIL) and [N1888][NTf2] (AIL) at 1%, 5%, and 10% weight concentration. The lubricant samples are validated for corrosion, four ball tribology and tapping torque experiments. Using optical microscope, profilometer, AFM, SEM, EDS and XPS analysis, worn surfaces were investigated. The lubrication performance of MJO+AIL10% and MJO+PIL1% samples provide competitive lubrication performance to that other lubricant samples used herein. They have shown improved corrosion inhibition, superior friction reduction, lower worn surface area, excellent surface finish and increased tapping torque efficiency. These superior tribological results correspond to the metal oxide tribofilm formation and anti-corrosion behavior of MJO+AIL10% sample.
Environmental and Ecological issues call for the reduction in usage of cutting fluids in metal cutting industry. New techniques are being inquired to achieve this objective. Hard turning with minimum quantity lubrication is one such technique which can alleviate the pollution problems associated with cutting fluids. In the present work, vegetable oil based cutting fluids like castor oil, palm oil and ground nut oil is made to drop at tool-work interface using over-head system. The present paper deals with experimental investigation carried out for machinability study of AISI D3 steel in combination with CVD coated cemented carbide inserts of different styles and to obtain optimum process parameters using TOPSIS and Desirability function analysis. An orthogonal array, closeness coefficient, composite desirability and analysis of variance (ANOVA) are applied to study the performance of process parameters such as insert style, cutting fluid cutting speed, feed and depth of cut with consideration of quality characteristics i.e., Surface roughness, material removal rate and specific energy. Finally a clear comparison is presented between DFA and TOPSIS
In consideration of the important role of environmentally benign metalworking fluid (MWF) in the machining industry, jatropha oil has been acknowledged as a suitable type of lubrication based oil. Despite its advantages, crude jatropha oil (CJO) had its main drawback in terms of poor thermal-oxidative stability due to the presence of unsaturated molecules that leads to oxidation reaction. The objective of this study was to evaluate the physicochemical properties and tapping torque of newly developed modified jatropha oils (MJOs). Initially, CJO was chemically modified through the transesterification process at various molar ratios of jatropha methyl ester (JME) to trimethylolpropane (TMP) to produce a series of MJOs denoted as MJO1, MJO3, and MJO5. Hexagonal boron nitride particles at concentrations of 0.05, 0.1 and 0.5 wt% were mixed with the MJOs. MJOs with and without hBN particles were analysed based on the physicochemical testing (i.e., acid value, viscosity, viscosity index (VI) and flash point) and tapping torque test (i.e., tapping torque, thrust force and tapping torque efficiency). Experimental results showed an improvement of physicochemical properties of these newly developed MWFs with the increase in JME:TMP molar ratio and concentration of hBN particles. MJO5 displayed the best physicochemical properties with the highest VI of 196, compared with MJO3 and MJO1. The addition of 0.5 wt% of hBN particles in MJO5 (MJO5c) caused the highest VI achieved at 228, compared with the other samples. The average tapping torque and thrust force were reduced approximately by 15% and 45%, respectively using MJO5a (0.05 wt% of hBN particles with MJO5), compared with SE. MJO5a also demonstrated an improvement of 118% tapping torque efficiency that indicated an excellent machining performance. In conclusion, MJOs containing hBN particles showed better performances on the lubricating property. Among the samples, MJO5a could be proposed to substitute synthetic ester as a sustainable MWF for machining processes.
General speaking, metalworking mass production techniques can be traced back to the 16th century, but it was really not until the late 18th century that engineers in the industrialised countries paid close attention to increasing production, due to the vast rise in their populations and significant industrial growth. In Europe at that time, two countries where important areas of applied machining and fluid research were being pursued was: in France, where the machining of metals was being investigated and developed into a science – specifically in terms of the effects of tool feeding and lubrication and its affect on surface finish; also in the mid-19th century in England, where the effects of water as a coolant to enhance tool performance was also studied. Thus, as these research activities progressed, complementary advances were taking place into the study of tool materials their heat treatment and in particular, tool hardening techniques. As has happened on many occasions in the past, considerable advances took place as a result of the enormous demands for armament manufacturers and their production needs during times of war, significantly adding advancements and refinements to the: machine tools; tooling; as well as for lubricants.
Huge quantity of petroleum and mineral based cutting fluids mixed with carcinogenic additives to increase their performance are used every year in the manufacturing industry. Application of such fluids poses a serious hazard to the environment, workers and personnel who directly or indirectly come in contact with them. Disposal of these cutting fluids without neutralization has a high potential of contaminating the water bodies and affect the aquatic life. Various vegetable based cutting fluids have been formulated from edible oils but less work is reported on non edible oils. In this work non edible neem oil was used as a base oil and a food grade emulsifier was used. Thus the cutting fluid is totally biodegradable. Various cutting fluids were formulated and then experiments were done on EN8 with uncoated carbides on lathe machine and various results reported. The neem oil has inherent anti microbial properties and thus prevents microbial contamination for a long period of time. This newly developed cutting fluid does not require any neutralization before disposal.
Lubricants are used globally in wide range of applications varying from smaller to larger industrial machinery units under differentworking conditions. Lossof toxic lubricants in to the environment during usage owing to mishandling, accidental spillages, leaks, evaporation and other miscellaneous reasons hasresulted in rising environmental concerns. Escalating crude oil prices have further aggravated the problem to renew interest in development and usage of alternative resourceswhich are environmental friendly and acceptable.Owing to certain inherent technical properties and their ability towards biodegradability; vegetable oils possess potential as alternatives to reduce dependency on mineral oil for lubricant formulations. In present investigation, wear performance of castor oil based lubricant has been examined for low speed applications.The experimental testswere carried on the basis of Taguchi’s L16orthogonal array considering the influence of prominent variable operating factors load, speed and blending ratio. Using Taguchi optimization method, optimum combination of these three factors have been reported.Wear performance of castor oil based lubricant in varying blending ratio viz; tribological poperties like coefficient of friction and wear scarhave been analyzed in four ball testing machine through experimental design prepared by Taguchi technique.
Since, worldwide, the proportion of metalworking fluids formulated without mineral oil content (so-called fully synthetic cutting fluids) only amounts to 5-15%, the emulsions are quite clearly the most important products. There have been very different ideas on the action mechanism of cutting fluids over the last few years. It is mainly assumed that cooling alone reduces wear at high cutting speeds. The most broadly used rapid testing method applied for many years to assess cutting fluids is the so-called tapping-torque test. This chapter describes the most important emulsifier groups for metalworking and shows the chemical structures of ionic and non-ionic emulsifiers. It defines the most significant differences according to concentrates and water-mixed finished products and the terms non-water-miscible coolants and water-miscible coolants. The chapter discusses the methods of testing to establish the physical stability as well as other key stability values of metalworking emulsions, and deals with special application methods for metalworking emulsions.
Advanced Machining Processes of Metallic Materials: Theory, Modelling and Applications, Second Edition, explores the metal cutting processes with regard to theory and industrial practice. Structured into three parts, the first section provides information on the fundamentals of machining, while the second and third parts include an overview of the effects of the theoretical and experimental considerations in high-level machining technology and a summary of production outputs related to part quality. In particular, topics discussed include: modern tool materials, mechanical, thermal and tribological aspects of machining, computer simulation of various process phenomena, chip control, monitoring of the cutting state, progressive and hybrid machining operations, as well as practical ways for improving machinability and generation and modeling of surface integrity. This new edition addresses the present state and future development of machining technologies, and includes expanded coverage on machining operations, such as turning, milling, drilling, and broaching, as well as a new chapter on sustainable machining processes. In addition, the book provides a comprehensive description of metal cutting theory and experimental and modeling techniques, along with basic machining processes and their effective use in a wide range of manufacturing applications. The research covered here has contributed to a more generalized vision of machining technology, including not only traditional manufacturing tasks, but also potential (emerging) new applications, such as micro and nanotechnology. Includes new case studies illuminate experimental methods and outputs from different sectors of the manufacturing industry Presents metal cutting processes that would be applicable for various technical, engineering, and scientific levels Includes an updated knowledge of standards, cutting tool materials and tools, new machining technologies, relevant machinability records, optimization techniques, and surface integrity.
The effective disposal of waste cutting fluid has received increasing attention in recent years. This study focuses on the treatment of waste cutting fluid by freeze-thaw method. The influences of freezing medium, freezing temperature, freezing time, NaCl content and pH on treatment efficiency were studied. The COD removal rate of waste cutting fluid was about 80% and oil recovery reached 3700 mg/L at the freezing temperature of −8 °C for 8 h without NaCl addition or pH adjustment. The micrograms of initial and treated waste cutting fluid showed that the particles of oil droplets in wastewater were significantly larger after freeze-thaw process and easier to gather and separation. Infrared spectroscopy studies indicated that the oil recovered from waste cutting fluid precipitation was mainly composed of esters. Up to 3.7 kg fat extract was recovered from 1 m³ of waste cutting fluid, while the required power of this freezing process is 42.90 kW h by theoretical calculation. Thus, freeze-thaw method appears to be effective and feasible for waste cutting fluid treatment.
This chapter provides comprehensive knowledge regarding cutting fluids (CFs), their classifications and basic categories, including non-water-miscible, water-miscible and water-based CFs. Main properties and application areas of these three CFs are characterized and specified. Such effects as cooling, lubricating and processing (i.e., the influence on the behaviour of the cutting process) resulting from supplying CFs are outlined. The strategies of delivering CFs to the cutting zone, including flooding, external and internal supply of pressured CFs, along with minimum-quantity lubrication techniques as well as cryogenically cooled gases (CO2 snow and liquid nitrogen (LN2)) are described. Some advanced constructions of cutting tools (such as turning tools, deep hole drills and milling cutters) allowing the application of high-pressure cooling, along with relevant fluid delivery systems offered by the world-leading cutting tools’ manufacturers, are presented. Similarly, cutting tools and installations for cryogenic machining used for turning and milling operations of different machined materials including Inconel and titanium alloys are outlined. The environmental issues related to the maintenance and disposal CFs are specified and discussed.
This paper reviews recent progress and applications of nanofluids in machining processes. In addition to reviewing the various conventional and advanced cooling techniques during machining, the paper also discusses the preparation methods, factors for enhancing thermal conductivity and properties of nanofluids. In line with fast development of nanofluid in machining process, the purpose of this paper is to review recent progress on the application of nanoparticles in lubricants especially for MQL technique. The conclusions and important summaries were also presented according to the data collected.