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Methods of Application of Cutting Fluids in Machining

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A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (30 September 2023) | Viewed by 19286

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Special Issue Editors

Prof. Dr. Alisson Rocha Machado

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Guest Editor

1. Graduate Program in Mechanical Engineering, Pontifícia Universidade Católica do Paraná—PUC-PR, R. Imaculada Conceição, 1155, Bairro Prado Velho, Curitiba 80215-901, Brazil
2. School of Mechanical Engineering, Federal University of Uberlandia, Av. João Naves de Ávila, 2121, Bloco 1M, Uberlândia 38400-902, Brazil
Interests: machining; cutting fluids; chip formation; tool wear; surface integrity; tribology
Special Issues, Collections and Topics in MDPI journals

Dr. Leonardo Rosa Ribeiro da Silva

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Guest Editor

School of Mechanical Engineering, Federal University of Uberlândia, Uberlândia 38408-144, MG, Brazil
Interests: surface engineering; lubrication; manufacturing; machining; tribology
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The use of cutting fluids in machining is mandatory in most processes, enhancing tool life, reducing heat generation, diminishing force and power consumption, and improving the surface quality of the workpieces. Examples of this can be seen in the continuous cutting (e.g., turning, boring, and drilling) of steel, titanium, and nickel-based superalloys with cemented carbide tools, or when tight tolerances are required. On the other hand, in some application, the use of a cutting fluid is prohibited because it adversely affects the machining process, for example, when ceramic tools are used, in turning hardened steels, and when thermal cracks are the prevailing wear damage. Finally, there are occasions that the application of a cutting fluid is innocuous, that is, no gain or loss would occur. Examples of this are in the machining of grey cast iron, aluminium, and magnesium alloys. When a cutting fluid is required, its efficiency depends on the correct choice and the way it is applied, including the method, direction, and flow rate or pressure. Methods currently used industrially or in machining labs all over the world include conventional flood cooling (CFC), minimum quantity lubrication (MQL), minimum quantity cooling lubrication (MQCL), nanoMQL, biodegradable MQL, cryogenic cooling lubrication (CCL), and high-pressure cooling (HPC). Issues affecting the sustainability of the processes are relevant and must be at the forefront of focus when deciding on an application method.

In this Special Issue, the objective is to publish high-quality papers covering relevant aspects of the method of cutting fluid application in the machining of any type of work material (ferrous and nonferrous metals and alloys), using any type of tool material in any type of machining process. We are searching for articles scientifically studying important aspects of cooling and lubricating actions of cutting fluids applied using different methods, and ones which can answer the following questions: How can the method of cutting fluid application reduce tool wear? How can the method of cutting fluid application reduce the cutting temperature? How can the method of cutting fluid application reduce cutting forces and power consumption? How can the method of cutting fluid application enhance the surface quality of a machined workpiece? How can the method of cutting fluid application improve environmental issues? How can the method of cutting fluid application reduce machining costs? This Special Issue aims to provide answers to all these questions through a substantially large discussion forum concerning the manufacturing community.

Prof. Dr. Alisson Rocha Machado
Dr. Leonardo Rosa Ribeiro da Silva
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

cutting fluids
conventional flood cooling system
minimum quantity lubrication (MQL)
minimum quantity cooling lubrication (MQCL)
nanofluid applied with MQL (nanoMQL)
biodegradable MQL
cryogenic cooling lubrication (CCL)
high-pressure cooling (HPC)
tool life and tool wear
cutting temperature
cutting force and power consumption
workpiece surface quality

Published Papers (11 papers)

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Research

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13 pages, 6056 KiB

Open AccessArticle

An Experimental Investigation on the Effects of the Base Fluid of External Fluid and Voltage on the Milling Performance of Nanofluid Composite Electrostatic Spraying

by Yu Su, Qingxiang Yang, Pan Liu and Jiaxi You

Lubricants 2023, 11(10), 447; https://doi.org/10.3390/lubricants11100447 - 16 Oct 2023

Viewed by 1342

Abstract

Nanofluid composite electrostatic spraying (NCES) is a new clean machining technology for minimum quantity lubrication. The base fluid of external fluid and voltage are the two important parameters that affect its performance. This study presented the effect of base fluid of external fluid on milling force and temperature of NCES to determine the suitable base fluid and the best external/internal fluid. Herein, castor oil, castor oil-based nanofluid, sunflower oil, and sunflower oil-based nanofluid were employed as external fluid, and water and water-based nanofluid as internal fluid. Atomization experiments were conducted to determine the common voltage for different external/internal fluids to generate an applicable atomization mode. Under this voltage, morphology of applicable atomization mode, current and standard deviation, droplet speed, and electrowetting contact angle were explored to discuss the effect of base fluid on NCES milling. Next, the best external/internal fluid was used to further investigate the milling force and temperature under various voltages. Sunflower oil was the suitable base fluid for NCES, and sunflower oil-based nanofluid/water-based nanofluid was found to be the best external/internal fluid causing a significant reduction in force and temperature. Compared to castor oil, sunflower oil as the base fluid lowered the milling force and temperature by 5.4–10.8% and 6.3–7.9%, respectively. Within the voltage range of applicable atomization mode, raising the voltage lowered the milling force and temperature by 2.4% and 3.9%, respectively. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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23 pages, 8076 KiB

Open AccessArticle

Exploring the Impact of the Turning of AISI 4340 Steel on Tool Wear, Surface Roughness, Sound Intensity, and Power Consumption under Dry, MQL, and Nano-MQL Conditions

by Yusuf Fedai

Lubricants 2023, 11(10), 442; https://doi.org/10.3390/lubricants11100442 - 12 Oct 2023

Cited by 1 | Viewed by 1229

Abstract

Optimizing input parameters not only improves production efficiency and processing quality but also plays a crucial role in the development of green manufacturing engineering practices. The aim of the present study is to conduct a comparative evaluation of the cutting performance and machinability process during the turning of AISI 4340 steel under different cooling conditions. The study analyzes cutting operations during turning using dry, minimum quantity lubrication, and nano- minimum quantity lubrication. As control parameters in the experiments, three different cooling types, cutting speeds (100, 150, 200 m/min), and feed rate (0.1, 0.15, 0.20 mm/rev) levels were applied. The experimental results show that the optimal output values are found to be Vb = 0.15 mm, Ra = 0.81µm, 88.1 dB for sound intensity and I = 4.18 A for current. Moreover, variance analysis was performed to determine the effects of input parameters on response values. Under dry, minimum quantity lubrication, and nano-minimum quantity lubrication processing conditions, parameters affecting tool wear, surface roughness, current by the motor shaft, and sound level were examined in detail, along with the chip morphology. The responses obtained were optimized according to the Taguchi S/N method. As a result of optimization, it was concluded that the optimum values for cutting conditions were nano-minimum quantity lubrication cooling and V = 100 m/min, f = 0.1 mm/rev cutting. Finally, it was observed that there was a 13% improvement in tool wear, 7% in current, 9% in surface roughness, and 8% in sound intensity compared to the standard conditions. In conclusion, it was determined that nano-minimum quantity lubrication with the lowest level of cutting and feed rate values provided the optimum results. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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26 pages, 33723 KiB

Open AccessArticle

The Influence of Phosphate-Ester-Based Additives on Metal Cutting Fluid Behavior during the Machining of Titanium Alloy

by Junhui Ma, Javad Mohammadi, Olufisayo A. Gali and Reza A. Riahi

Lubricants 2023, 11(7), 301; https://doi.org/10.3390/lubricants11070301 - 19 Jul 2023

Viewed by 1030

Abstract

The behavior of four phosphate ester additives with varying levels of phosphorus concentrations (very high, high, medium, and low) was examined through the course of drilling a Ti-6Al-4V titanium alloy at a constant metal removal rate (4.2 mm³/s). Cutting fluid (CF) additives were evaluated using torque, specific cutting energy (SEC), and tool wear. The drilling conditions employed had a significant influence on the performance of the phosphate ester additives. At 0.105 m/s and 0.188 m/s, the phosphate ester with very high phosphorous levels possessed the lowest SCE and torque values. The high-phosphorous-level phosphate ester displayed enhanced drilling performance at 0.293 m/s. At 0.419 m/s, the SCE and torque performance of the medium-phosphorous-level phosphate ester was preferable. The drilling performance of the phosphorus esters was observed to be related to the working mechanisms of the additives, which, in turn, was associated with the formation of a phosphorus-rich tribolayer and an organophosphate tribolayer on the cutting blade. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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15 pages, 4956 KiB

Open AccessArticle

Tribological Effects of Metalworking Fluids in Cutting Processes

by Florian Pape, Gerhard Poll, Lars Ellersiek, Berend Denkena and Haichao Liu

Lubricants 2023, 11(5), 224; https://doi.org/10.3390/lubricants11050224 - 16 May 2023

Cited by 1 | Viewed by 1489

Abstract

An understanding of the proper application of metalworking fluids (MWFs) is necessary for their implementation in efficient production processes. In addition, the knowledge of the process-related aspect of chip transport and the macroscopic cooling effect, the characteristics and properties of lubricant film formation, and the cooling conditions in the secondary shear zone on the chip surface, i.e., in the direct vicinity of the material separation, represent a combined fundamental scientific issue within production engineering. The aim is to transfer methods from the field of tribology of machine elements, which have already led to a considerable gain in knowledge in this discipline, to machining and to couple them with already established approaches to machining. In the case of roller bearings, the contact pressure is in the range as the pressure in the contact zone between the cutting insert and chip. Due to this, established methods might be transferred to the cutting process. In addition to classical pin-on-plate and pin-on-ring friction investigations, film thickness measurements were carried out and compared to machining tests. The coefficient of friction determined in the planing test rig is 0.48 for dry cutting, while it is 0.47 for wet cutting. These two values are much larger than the CoF with MWFs measured on the two tribometers. It is shown that the boundary friction of MWF especially influences the machining process. Thus, additives in MWF might have a high significance in machining. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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23 pages, 12471 KiB

Open AccessArticle

Dry and MQL Milling of AISI 1045 Steel with Vegetable and Mineral-Based Fluids

by Vitor Baldin, Leonardo Rosa Ribeiro da Silva, Rahul Davis, Mark James Jackson, Fred Lacerda Amorim, Celso Ferraz Houck and Álisson Rocha Machado

Lubricants 2023, 11(4), 175; https://doi.org/10.3390/lubricants11040175 - 12 Apr 2023

Cited by 3 | Viewed by 1613

Abstract

The use of mineral-based cutting fluids in machining has the drawback of affecting the environment and industries are under pressures to reduce its use in favor of cleaner productions. In this regard, the vegetal-based cutting fluids can be a superior alternative, provided they improve the technical outcomes. In the milling process, dry cutting is commonly performed, however, the application of cutting fluids using the minimum quantity of lubricant (MQL) method has proven advantageous when compared with dry machining. Furthermore, in the midst of the availability of several cutting fluids in the market, the testing of their individual performance can ascertain their potential and effectiveness for a particular application. This study examined the performances of two vegetable-based and one mineral-based oils applied by the MQL method, followed by their comparison with dry cutting amid end milling of AISI 1045 steel with TiAlN-coated cemented carbide inserts. The cutting temperature, machining forces, power consumption, workpiece surface roughness, tool life, and tool wear mechanisms were chosen as the output parameters. The experiments were conducted using two cutting speeds (150 and 200 m/min) and feed rates (0.07 and 0.14 mm/tooth), and constant axial (1 mm) and radial depths of the cut (25 mm). The temperature was measured using a K-type thermocouple soldered to the part and an infrared camera. The power was monitored with a Fluke 435 energy analyzer, and the machining force components with a Kistler dynamometer. The worn inserts were inspected under a scanning electron microscope (SEM) to analyze the tool wear mechanism. The MQL-assisted application of the cutting fluids notably lowered the cutting temperature and increased the tools’ lives. However, the cutting fluids did not reflect any significant effect on the machining force, power consumption, or surface roughness. Among all the analyzed cutting conditions, the abrasive wear mechanism dominated, damaging the cutting edges, flank, and rake surfaces of the cutting tools. In addition, adhesive and diffusion wear mechanisms were also observed. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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14 pages, 8788 KiB

Open AccessArticle

Machinability Investigations Based on Tool Wear, Surface Roughness, Cutting Temperature, Chip Morphology and Material Removal Rate during Dry and MQL-Assisted Milling of Nimax Mold Steel

by Rüstem Binali, Havva Demirpolat, Mustafa Kuntoğlu and Hacı Sağlam

Lubricants 2023, 11(3), 101; https://doi.org/10.3390/lubricants11030101 - 26 Feb 2023

Cited by 18 | Viewed by 1777

Abstract

Using cutting fluids is considered in industrial applications and academia due to their increased influence over many aspects such as machinability, sustainability and manufacturing costs. This paper addresses the machinability perspective by examining indicators such as roughness, cutting temperature, tool wear and chip morphology during the milling of mold steel. A special type of steel is Nimaxm which is a difficult-to-cut material because of its high strength, toughness, hardness and wear resistance. Since mold steels have the reverse geometry of the components produced by this technology, their surface quality and dimensional accuracy are highly important. Therefore, two different strategies, i.e., dry and minimum quantity lubrication (MQL), were chosen to conduct an in-depth analysis of the milling performance during cutting at different cutting speeds, feed rates and cutting depths. Without exception, MQL technology showed a better performance than the dry condition in obtaining better surface roughnesses under different cutting parameters. Despite that only a small improvement was achieved in terms of cutting temperature, MQL was found to be successful in protecting the cutting tool from excessive amounts of wear and chips. This paper is anticipated to be a guide for manufacturers and researchers in the area of mold steels by presenting an analysis of the capabilities of sustainable machining methods. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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15 pages, 4070 KiB

Open AccessArticle

A Study on the Effects of Hybridized Metal Oxide and Carbonaceous Nano-Cutting Fluids in the End Milling of AA6082 Aluminum Alloy

by Vignesh S, Mohammed Iqbal U and Jaharah A. Ghani

Lubricants 2023, 11(2), 87; https://doi.org/10.3390/lubricants11020087 - 17 Feb 2023

Cited by 3 | Viewed by 1488

Abstract

Finding an alternate solution for supplanting the existing conventional lubricant in machining is a challenge. This work narrows the search down to the use of nano-cutting fluids, as they exhibit excellent properties such as high thermal conductivity and good lubricity. A technical analysis of the performance of hybrid nano-cutting fluids in the end milling of AA6082 aluminium alloy in a constrained end milling condition is presented. Alumina and carbon nanotubes were chosen in this study for their better physical characteristics and compatibility during machining. Coconut oil was chosen as the base fluid (dispersal medium) as it provides good lubricity and better dispersion of nanoparticles due to its excellent rheological behaviour. The hybrid nanofluid was prepared by mixing alumina-based nanofluid with carbon nanotube nanoparticles in different volumetric concentrations. The thermo-physical properties of the prepared hybrid nanofluid were tested. Furthermore, they were tested for their spread-ability and other mechanical properties. Later, their performances as cutting fluid were studied with the minimum quantity lubrication (MQL) technique, wherein nanoparticle mist was formed and evaluated in the end milling of AA6082 aluminium to reduce the quantity of nanofluids’ usage during end milling. The controllable parameters of speed, feed rate, and type of cutting fluid were chosen, with the levels of cutting speeds and feed rate at 75–125 m/min, and 0.005–0.015 mm/tooth, respectively, and the response parameters studied were surface roughness and tool wear. The results show that better performance is achieved in hybridized nano-cutting fluid, with a sharp improvement of 20%, and 25% in tool wear and surface roughness when compared to the base fluid. This study has explored the concept of hybridization and the capability of nanofluids as cutting fluids that can be used as eco-friendly cutting fluids in manufacturing industries. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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25 pages, 112854 KiB

Open AccessArticle

A Comparative Machinability Study of SS 304 in Turning under Dry, New Micro-Jet, and Flood Cooling Lubrication Conditions

by Barun Haldar, Hillol Joardar, Borhen Louhichi, Naser Abdulrahman Alsaleh and Adel Alfozan

Lubricants 2022, 10(12), 359; https://doi.org/10.3390/lubricants10120359 - 12 Dec 2022

Cited by 4 | Viewed by 2107

Abstract

The main objective of this experimental investigation is to examine favourable machining conditions by utilising fewer resources of machining industries for the techno-economical and ecological benefits. The machining operations are performed in turning SS 304 using coated carbide tool inserts under dry, water-soluble cutting fluid solution in the form of flood cooling and small-quantity lubrication (SQL) conditions by employing a newly formed micro-jet for a comparative classical chips study and analysis. The machining experiments are conducted in turning by a 25 kW precision CNC lathe with a special arrangement of micro-jets into the machining zone. Machining speeds and feed rates are varied under dry, micro-jet, and flood cooling conditions and their effects are studied on the type of chips and their morphology, chip reduction coefficient (ξ), and chip shear plane distance (d). The effect of machining environments on tool health conditions (such as BUEs, tool-edge chipping, and edge breaking) is examined for the inferences. In the range of low-speed machining (less than 600 m/min), metal cutting seems easier in flood cooling conditions, but it imposes more unfavourable effects (such as edge chipping and edge breaking) on the ceramic cutting tool’s health. On the other hand, the dry machining condition shows a favourable performance for a ceramic cutting tool. The optimum machining condition is found in the micro-jet SQL by the analysis of experimental data and observation results for the tool and work combination. The analysis of the results is carried out by the response surface methodology (RSM) and artificial neural network (ANN). The ANN model is found to be more accurate than RSM. The aspects of effective green machining are emphasised. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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22 pages, 8010 KiB

Open AccessArticle

Flooding Application of Vegetable- and Mineral-Based Cutting Fluids in Turning of AISI 1050 Steel

by Déborah Oliveira Almeida Carvalho, Leonardo Rosa Ribeiro da Silva, Felipe Chagas Rodrigues de Souza, Pedro Henrique Pires França, Álisson Rocha Machado, Eder Silva Costa, Gustavo Henrique Nazareno Fernandes and Rosemar Batista da Silva

Lubricants 2022, 10(11), 309; https://doi.org/10.3390/lubricants10110309 - 14 Nov 2022

Cited by 6 | Viewed by 1677

Abstract

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 eco-friendlier 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. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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21 pages, 8395 KiB

Open AccessArticle

Influence of Graphene Nanosheets on Thermo-Physical and Tribological Properties of Sustainable Cutting Fluids for MQL Application in Machining Processes

by Vitor Baldin, Leonardo Rosa Ribeiro da Silva, Rogério Valentim Gelamo, Andres Bustillo Iglesias, Rosemar Batista da Silva, Navneet Khanna and Alisson Rocha Machado

Lubricants 2022, 10(8), 193; https://doi.org/10.3390/lubricants10080193 - 21 Aug 2022

Cited by 8 | Viewed by 1825

Abstract

The growing need to increase productivity and pressures for more sustainable manufacturing processes lead to a shift to less harmful lubrication systems that are less harmful to nature and the people involved. The minimal quantity lubrication system (MQL) stands out in this respect, especially in interrupted cutting processes such as milling, due to the cutting interface’s highly dynamic and chaotic nature. Using graphene sheets in cutting fluids also increases the efficiency of machining processes. This work investigates the influence on thermophysical and tribological properties of concentrations of 0.05 wt% and 0.1 wt% of graphene sheets in two vegetable-based and one mineral-based cutting fluids. The fluids are first characterized (viscosity, thermal conductivity, diffusivity, and wettability) and tested in reciprocating and ramp milling tests; all experiments are based on norms. The results show that the experiments with cutting fluids (with and without graphene) showed better tribological behavior than those in dry conditions. The graphene sheets alter the thermo-physical and tribological properties of the cutting fluids. The MQL15 vegetable-based fluid showed better lubricating properties in the milling tests, with better conditions for tribosystem chip–tool–workpiece interfaces, which makes the friction coefficient, and wear rate stable. Vegetable-based cutting fluids, even in minimum quantities and with graphene nanoparticles, have a high potential for increasing the efficiency and sustainability of the milling process. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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Review

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64 pages, 34892 KiB

Open AccessReview

Current Status of Hard Turning in Manufacturing: Aspects of Cooling Strategy and Sustainability

by Rajashree Mallick, Ramanuj Kumar, Amlana Panda and Ashok Kumar Sahoo

Lubricants 2023, 11(3), 108; https://doi.org/10.3390/lubricants11030108 - 27 Feb 2023

Cited by 17 | Viewed by 2344

Abstract

In recent years, hard turning has been found to be a well-known substitute for traditional grinding for acquiring the finish quality of hardened steel without sacrificing productivity. There are many issues that should be carefully understood and dealt with to attain efficacious performance in hard turning. This article discusses modern manufacturing challenges with a focus on analyzing the current state of the art of the hard turning process in terms of ensuring more environmentally friendly manufacturing through the use of greener cooling methods such as dry, wet/flood cooling, the minimum quantity of lubricant (MQL), high-pressure jet cooling, solid lubricant, nanofluids, ionic liquids (ILs), cryogenic cooling, and hybrid cooling. Nanofluids combined with the MQL system were found to be the superior cooling technique in comparison to dry, wet/flood, and MQL. Cryo-machining also provided superior performance by limiting the cutting temperature during hard turning. The performance of hybrid cooling (MQL + cryogenic) seems to have been superior to MQL and cryogenic coolant alone because it combined the benefits of lubrication and cooling from MQL and cryogenic systems, respectively. The addition of ILs to base fluids or nanofluids improves the thermal properties of the mixed fluid, resulting in better surface quality, lower tool wear, and longer tool life. Furthermore, the purpose of this study is to summarize the various LCA software used for analyzing the sustainability of the hard turning process. Overall, this paper can serve as a resource for researchers and manufacturers working in the field of sustainable machining. Full article

(This article belongs to the Special Issue Methods of Application of Cutting Fluids in Machining)

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