Minimum Quantity Lubrication (MQL) Using Vegetable Oil With Nano-Platelet Solid Lubricant in Milling Titanium Alloy

Improving the machinability of titanium (Ti) alloys remains unresolved for manufacturing industries because excessive tool wear and catastrophic tool failures lead to shortened tool life and low productivity with any available cutting tool system. Besides optimizing the substrate and/or coating materials for cutting tools, improving the cooling and lubricating conditions is one of the ways to improve the machinability of Ti alloys. In this paper, we explore the possibility of using a nano-platelet, lamellar-type solid lubricant of graphite Exfoliated graphite nano-platelets (xGnP®) grade C750 (or xGnP750) in Minimum Quantity Lubrication (MQL) machining of Ti-6Al-4V (Ti64). Due to the lamellar or layered crystal structure, each layer easily slides against adjacent layers to provide the lubricity when introduced at the tool/work material interface. Although the nano-platelets have a nano-thickness, they have a micro-sized diameter, which prevents the nano-platelets from penetrating through human skin and breathing through nose. This makes the great advantage in this approach compared to other nano-enhanced MQL processes. The milling experiment shows that the nano-platelets present in the MQL oil decreased flank wear and improved the tool life compared to traditional MQL with pure oil as well as dry machining. The presence of nano-platelets reduces the micro chipping and tool fracture caused by the effect of impact in interrupted machining.

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Experimental Results on Lamellar-Type Solid Lubricants in Enhancing Minimum Quantity Lubrication Machining

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4033995 ◽

2016 ◽

Vol 138 (10) ◽

Cited By ~ 2

Author(s):

Trung Kien Nguyen ◽

Kyung-Hee Park ◽

Patrick Y. Kwon

Keyword(s):

Vegetable Oil ◽

Solid Lubricant ◽

Minimum Quantity Lubrication ◽

Solid Lubricants ◽

Machining Process ◽

Minimum Quantity ◽

Aspect Ratios ◽

Significant Difference ◽

1045 Steel ◽

Lamellar Type

This paper studies the effect of various lamellar-type solid lubricants (graphite and hBN) that can be mixed into a lubricant to potentially improve the machinability of minimum quantity lubrication (MQL) machining. To examine this, the solid lubricants are classified into particles and platelets based on their aspect ratios as well as their respective sizes. In particular, the particles are classified into microparticles and nanoparticles based on their dimensions (average radius), while the platelets were classified, based on their average thickness, into two types: the “microplatelets” if the thickness is typically up to few tens of microns and the “nanoplatelets” if the thickness is well below a tenth of a micron (even down to few nanometers). Our previous work has shown that the mixture of an extremely small amount (about 0.1 wt. %) of the graphitic nanoplatelets and vegetable oil immensely enhanced the machinability of MQL machining. In this paper, many lubricants, each mixed with a particular variety of nano- or micro-platelets or one type of nanoparticles, were studied to reveal the effect of each solid lubricant on MQL machining. Prior to the MQL machining experiment, the tribological test was conducted to show that the nanoplatelets are overall more effective than the microplatelets and nanoparticles in minimizing wear despite of no significant difference in friction compared to pure vegetable oil. Consequently, the MQL ball-milling experiment was conducted with AISI 1045 steel yielding a similar trend. Surprisingly, the oil mixtures with the microplatelets increased flank wear, even compared to the pure oil lubricant when the tools with the smooth surface were used. Thus, the nanoscale thickness of these platelets is a critical requirement for the solid lubricants in enhancing the MQL machining process. However, maintaining the nanoscale thickness is not critical with the tools with the rough surfaces in enhancing the MQL process. Therefore, it is concluded that finding an optimum solid lubricant depends on not only the characteristics (material as well as morphology) of solid lubricants but also the characteristic of tool surface.

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Application of Minimum Quantity Lubrication for Drum High Clutch in Turning Process

Materials Science Forum ◽

10.4028/www.scientific.net/msf.947.160 ◽

2019 ◽

Vol 947 ◽

pp. 160-166

Author(s):

Nutrada Khumjeen ◽

Somkiat Tangjitsitcharoen

Keyword(s):

Tool Life ◽

Feed Rate ◽

Cutting Tool ◽

Cutting Tools ◽

Cutting Speed ◽

Minimum Quantity Lubrication ◽

Cutting Fluid ◽

Cutting Condition ◽

Turning Process ◽

Minimum Quantity

The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.

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Improvement in machining process performance using solid lubricant assisted minimum quantity lubrication

Advances in Materials and Processing Technologies ◽

10.1080/2374068x.2021.1882123 ◽

2021 ◽

pp. 1-26

Author(s):

Mayurkumar A. Makhesana ◽

Kaushik M. Patel

Keyword(s):

Solid Lubricant ◽

Minimum Quantity Lubrication ◽

Machining Process ◽

Process Performance ◽

Minimum Quantity

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Flank-milling of Integral Blade Rotors made in Ti6Al4V using cryo CO2 and Minimum Quantity Lubrication (MQL)

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4050548 ◽

2021 ◽

pp. 1-16

Author(s):

Haizea Gonzalez ◽

Octavio Pereira ◽

Luis Norberto López de Lacalle ◽

Amaia Calleja ◽

Izaro Ayesta ◽

...

Keyword(s):

Gas Turbines ◽

Cutting Tools ◽

Minimum Quantity Lubrication ◽

Cryogenic Cooling ◽

Flank Milling ◽

New Device ◽

Minimum Quantity ◽

Cutting Zone ◽

Oil Emulsions ◽

Pcd Tools

Abstract This paper presents the machining of Ti6Al4V Integral Blade Rotors (IBR) using CO2 as cryogenic cooling. This kind of component is typical in gas turbines, pumps and other rotary machines. Flank milling technique using diamond polycrystalline (PCD) tools using CO2 and Minimum Quantity Lubrication (MQL), denominated CryoMQL, is an alternative to conventional oil emulsions. The proposed approach implies a balance between technical and environmental issues, and it makes feasible the use PCD tools avoiding the high temperature reactivity of Ti6Al4V alloy with this type of cutting tools. CO2 must be supplied and injected onto the cutting zone, avoiding the risks of dry ice formation and clogging of both pipes and nozzles. For this purpose, a new device for CO2 delivery was developed, using gas and liquid CO2.

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Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools

Advances in Mechanical Engineering ◽

10.1177/1687814017710618 ◽

2017 ◽

Vol 9 (7) ◽

pp. 168781401771061 ◽

Cited By ~ 15

Author(s):

Duc Tran Minh ◽

Long Tran The ◽

Ngoc Tran Bao

Keyword(s):

Surface Roughness ◽

Tool Life ◽

Minimum Quantity Lubrication ◽

High Hardness ◽

Cemented Carbide ◽

Cutting Fluid ◽

Hard Milling ◽

Minimum Quantity ◽

Coated Carbide ◽

Lubrication Conditions

In this article, an attempt has been made to explore the potential performance of Al2O3 nanoparticle–based cutting fluid in hard milling of hardened 60Si2Mn steel (50-52 HRC) under different minimum quantity lubrication conditions. The comparison of hard milling under minimum quantity lubrication conditions is done between pure cutting fluids and nanofluids (in terms of surface roughness, cutting force, tool wear, and tool life). Hard milling under minimum quantity lubrication conditions with nanofluid Al2O3 of 0.5% volume has shown superior results. The improvement in tool life almost 177%–230% (depending on the type of nanofluid) and the reduction in surface roughness and cutting forces almost 35%–60% have been observed under minimum quantity lubrication with Al2O3 nanofluids due to better tribological behavior as well as cooling and lubricating effects. The most outstanding result is that the uncoated cemented carbide insert can be effectively used in machining high-hardness steels (>50 HRC) while maintaining long tool life and good surface integrity (Ra = 0.08–0.35 µm; Rz = 0.5–2.0 µm, equivalent to finish grinding) rather than using the costlier tools like coated carbide, ceramic, and (P)CBN. Therefore, using hard nanoparticle–reinforced cutting fluid under minimum quantity lubrication conditions in practical manufacturing becomes very promising.

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