Skip to main content
SpringerLink
Log in

Milling force and surface morphology of 45 steel under different Al2O3 nanofluid concentrations

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Nanofluid minimum quantity lubrication (NMQL) is a resource-saving, environment-friendly, and efficient green processing technology. Cottonseed oil can form a strong lubricating film owing to its abundant saturated fatty acids and monounsaturated fatty acids, which have excellent lubricating properties. The physical and chemical properties of nanofluids change when Al2O3 nanoparticles are added. However, the effects of cottonseed oil–based Al2O3 nanofluid concentrations on the milling force and workpiece surface quality remain unclear. To address this limitation, 45 steel was used to conduct NMQL milling experiments of cottonseed oil–based Al2O3 nanofluids with different mass fractions. Results showed that the minimum milling force was obtained at a concentration of 0.2 wt% (Fx = 58 N, Fy = 12 N). The minimum surface roughness value (Ra = 1.009 μm, RSm = 0.136 mm) was obtained at a mass concentration of 0.5 wt%, and the micromorphology of the workpiece/chip was optimal.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Abbreviations

MQL:

Minimum quantity lubrication

SEM:

Scanning electron microscope

W s :

Rotation rate (r/min)

V f :

Feed rate (mm/min)

V :

Cutting speed

a p :

Axial depth of cut (mm)

a e :

Radial depth of cut (mm)

α :

Angle of the nozzle and the cutter feeding direction

β :

Angle of nozzle and horizontal direction

γ :

Cut in angle

Fx, Fy, Fz :

Cutting force component in the X, Y, and Z directions (N)

NMQL:

Nanofluid minimum quantity lubrication

\( {\overline{F}}_{\mathrm{max}} \) :

Mean of milling force peak (N)

R a :

Arithmetic average height (μm)

RS m :

Mean spacing at mean line (mm)

R mr :

Bearing length ratio

μ n :

Viscosity of the nanofluid

μ bf :

Viscosity of the base fluid

\( R{S}_m=\frac{1}{N}\sum \limits_{i=1}^n{S}_i \) :

Nanoparticle mass fraction

γ sv :

Surface tension at the solid–gas interface

γ sl :

Surface tension at the solid–liquid interface

γ vl :

Surface tension at the gas–liquid interface

θ :

Contact angle

References

  1. Zhang JC, Li CH, Zhang YB, Yang M, Jia DZ, Hou YL, Li RZ (2018) Temperature field model and experimental verification on cryogenic air nanofluid minimum quantity lubrication grinding. Int J Adv Manuf Technol 97(1–4):209–228

    Google Scholar 

  2. Li HN, Yang Y, Zhao YJ, Zhang ZL, Zhu WQ, Wang WL, Qi H (2019) On the periodicity of fixed-abrasive planetary lapping based on a generic model. J Manuf Process 44:271–287

    Google Scholar 

  3. Guo SM, Li CH, Zhang YB, Yang M, Jia DZ, Zhang XP, Liu GT, Li RZ, Bing ZR, Ji HZ (2018) Analysis of volume ratio of castor/soybean oil mixture on minimum quantity lubrication grinding performance and microstructure evaluation by fractal dimension. Industrial Crops & Products 111:494–505

    Google Scholar 

  4. Hamdan A, Sarhan AAD, Hamdi M (2012) An optimization method of the machining parameters in high-speed machining of stainless steel using coated carbide tool for best surface finish. Int J Adv Manuf Technol 58(1–4):81–91

    Google Scholar 

  5. Mao C, Sun XL, Huang H, Kang CW, Zhang MJ, Wu YQ (2016) Characteristics and removal mechanism in laser cutting of cBNWC-10Co composites. J Mater Process Technol 230:42–49

    Google Scholar 

  6. Mao C, Zhang MJ, Zhang J, Tang K, Gan HY, Zhang GF (2015) The effect of processing parameters on the performance of spark plasma sintered CBN-WC-Co composites. J Mater Eng Perform 24:4612–4619

    Google Scholar 

  7. Li CH, Li JY, Wang S, Jia DZ (2013) Modeling and numerical simulation of the grinding temperature distribution with nanoparticle jet of MQL. Adv in Mech Eng 7:167–181

    Google Scholar 

  8. Zhang DK, Li CH, Zhang YB, Jia DZ, Zhang XW (2015) Experimental research on the energy ratio coefficient and specific grinding energy in nanoparticle jet MQL grinding. Int J Adv Manuf Technol 78(5–8):1275–1288

    Google Scholar 

  9. Yang M, Li CH, Zhang YB, Wang YG, Li BK, Jia DZ, Hou YL, Li RZ (2017) Research on microscale skull grinding temperature field under different cooling conditions. Appl Therm Eng 126:525–537

    Google Scholar 

  10. Tawakoli T, Hadad MJ, Sadeghi MH, Daneshi A, Stöckert S, Rasifard A (2009) An experimental investigation of the effects of workpiece and grinding parameters on minimum quantity lubrication—MQL grinding. Int J Mach Tool Manu 49(12–13):924–932

    Google Scholar 

  11. Mao C, Zhou X, Yin LR, Zhang MJ, Tang K, Zhang J (2016) Investigation of the flow field for a double-outlet nozzle during minimum quantity lubrication grinding. Int J Adv Manuf Technol 85:291–298

    Google Scholar 

  12. Zhu LD, Yang ZC, Li ZB (2018) Investigation of mechanics and machinability of titanium alloy thin-walled parts by CBN grinding head. Int J Adv Manuf Techno 100(9/12):2537-2555

  13. Davim JP, Sreejith PS, Gomes R, Peixoto C (2006) Experimental studies on drilling of aluminium (AA1050) under dry, minimum quantity of lubricant, and flood-lubricated conditions. Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture 220(10):1605–1611

    Google Scholar 

  14. Lv HG (2012) Tool wear of H13 steel hard milling process and its effect on the surface integrity. Shan Dong University 99. https://doi.org/10.7666/d.Y2179339

  15. M'Saoubi R, Axinte D, Soo SL, Nobel C, Attia H, Kappmeyer G, Engin S, Sim WM (2015) High performance cutting of advanced aerospace alloys and composite materials. CIRP Ann Manuf Technol 64:2

    Google Scholar 

  16. Silva LR, Bianchi EC, Fusse RY, Catai RE, França TV, Aguiar PR (2007) Analysis of surface integrity for minimum quantity lubricant—MQL in grinding. Int J Mach Tool Manu 47(2):412–418

    Google Scholar 

  17. Debnath S, Moola M, Qua S (2014) Environmental friendly cutting fluids and cooling techniques in machining: a review. J Clean Prod 83(83):33–47

    Google Scholar 

  18. Legutko S, Krolczyk J B, Krolczyk G M, Wojciechowski S, Maruda R W, Nieslony P (2018) Parametric and nonparametric description of the surface topography in the dry and MQCL cutting conditions.Measurement 121:225-239

  19. Mia M, Gupta MK, Singh G, Królczyk G, Pimeno DY (2018) An approach to cleaner production for machining hardened steel using different cooling-lubrication conditions. Journal of Cleaner Production 187:1069-1081

  20. Liao YS, Lin HM (2007) Mechanism of minimum quantity lubrication in high-speed milling of hardened steel. Int J Mach Tools Manuf 47(11):1660–1666

    Google Scholar 

  21. Liao YS, Lin HM, Chen YC (2007) Feasibility study of the minimum quantity lubrication in high-speed end milling of NAK80 hardened steel by coated carbide tool. Int J Mach Tools Manuf 47(11):1667–1676

    Google Scholar 

  22. Sarıkaya M, Güllü A (2014) Taguchi design and response surface methodology based analysis of machining parameters in CNC turning under MQL. J Clean Prod 65:604–616

    Google Scholar 

  23. Sarıkaya M, Güllü A (2015) Multi-response optimization of minimum quantity lubrication parameters using Taguchi-based grey relational analysis in turning of difficult-to-cut alloy Haynes 25. J Clean Prod 91:347–357

    Google Scholar 

  24. Lopez de Lacalle LN, Lamikiz A, Sánchez JA, Cabanes I (2001) Cutting conditions and tool optimization in the high-speed milling of aluminium alloys. Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture 215(9):1257–1269

    Google Scholar 

  25. Rahmati B, Sarhan AAD, Sayuti M (2014) Morphology of surface generated by end milling AL6061-T6 using molybdenum disulfide (MoS2) nanolubrication in end milling machining. J Clean Prod 66:685–691

    Google Scholar 

  26. Zhang S, Li JF, Wang YW (2012) Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions. Journal of cleaner production 32:81–87

    Google Scholar 

  27. Zhang YB, Li CH, Ji HJ, Yang XH, Yang M, Jia DZ, Zhang XP, Li RZ, Wang J (2017) Analysis of grinding mechanics and improved predictive force model based on material-removal and plastic-stacking mechanisms. Int J Mach Tools Manuf 122:81–97

    Google Scholar 

  28. Shahrom MS, Yahya NM, Yusoff AR (2013) Taguchi method approach on effect of lubrication condition on surface roughness in milling operation. Procedia Engineering 53(7):594–599

    Google Scholar 

  29. Kishawy HA, Dumitrescu M, Ng EG, Elbestawi MA (2005) Effect of coolant strategy on tool performance, chip morphology and surface quality during high-speed machining of A356 aluminum alloy. Int J Mach Tool Manu 45(2):219–227

    Google Scholar 

  30. Sharma VS, Dogra M, Suri NM (2009) Cooling techniques for improved productivity in turning. Int J Mach Tools Manuf 49(6):435–453

    Google Scholar 

  31. Uysal A, Demiren F, Altan E (2015) Applying minimum quantity lubrication (MQL) method on milling of martensitic stainless steel by using nano MoS2 reinforced vegetable cutting fluid. Procedia Soc Behav Sci 195:2742–2747

    Google Scholar 

  32. Ding WF, Zhu YJ, Zhang LC, Xu JH, Fu YC, Liu WD, Yang CY (2015) Stress characteristics and fracture wear of brazed CBN grains in monolayer grinding wheels. Wear 332–333:800–809

    Google Scholar 

  33. Setti D, Sinha MK, Ghosh S, Rao PV (2015) Performance evaluation of Ti–6Al–4V grinding using chip formation and coefficient of friction under the influence of nanofluids. Int J Mach Tools Manuf 88:237–248

    Google Scholar 

  34. Zhang YB, Li CH, Jia DZ, Zhang DK, Zhang XW (2015) Experimental evaluation of MoS2 nanoparticles in jet MQL grinding with different types of vegetable oil as base oil. J Clean Prod 87:930–940

    Google Scholar 

  35. Sharma AK, Tiwari AK, Dixit AR (2016) Effects of minimum quantity lubrication (MQL) in machining processes using conventional and nanofluid based cutting fluids: a review. J Clean Prod 127:1–18

    Google Scholar 

  36. Yin QA, Li CH, Zhang YB, Yang M, Jia DZ, Hou YL, Li RZ, Dong L (2018) Spectral analysis and power spectral density evaluation in Al2O3 nanofluid minimum quantity lubrication milling of 45 steel. Int J Adv Manuf Technol 97:129–145

    Google Scholar 

  37. Yin QA, Li CH, Dong L, Bai XF, Zhang YB, Yang M, Jia DZ, Hou YL, Liu YH, Li RZ (2018) Effects of the physicochemical properties of different nanoparticles on lubrication performance and experimental evaluation in the NMQL milling of Ti–6Al–4V. Int J Adv Manuf Technol 99:3091–3109

    Google Scholar 

  38. Wang YG, Li CH, Zhang YB, Yang M, Zhang XP, Zhang NQ, Dai JJ (2016) Experimental evaluation on tribological performance of the wheel/workpiece interface in minimum quantity lubrication grinding with different concentrations of Al2O3 nanofluids. J Clean Prod 142:3571–3583

    Google Scholar 

  39. Yang L (2013) Lubrication mechanism of vegetable oil based MQL cutting fluid and its applied fundamental research. Jiangsu University 83. https://doi.org/10.7666/d.Y2294076

  40. Wang X (2010) Lubrication characteristics of mixed fuel between cottonseed oil biodiesel and diesel. TRANSACTIONS OF THE CHINESE SOCIETY OF AGRICULTURAL ENGINEERING 26(3):272–276

    Google Scholar 

  41. Yang M, Li CH, Zhang YB, Jia DZ, Zhang XP, Hou YL, Li RZ, Wang J (2017) Maximum undeformed equivalent chip thickness for ductile-brittle transition of zirconia ceramics under different lubrication conditions. Int J Mach Tools Manuf 122:55–65

    Google Scholar 

  42. Zhang YB, Li CH, Jia DZ, Zhang DK, Zhang XW (2015) Experimental evaluation of the lubrication performance of MoS2/CNT nanofluid for minimal quantity lubrication in Ni-based alloy grinding. Int J Mach Tools Manuf 99:19–33

    Google Scholar 

  43. Hwang YK, Lee CM, Park SH (2009) Evaluation of machinability according to the changes in machine tools and cooling lubrication environments and optimization of cutting conditions using Taguchi method. Int J Precis Eng Manuf 10(3):65–73

    Google Scholar 

  44. Sayuti M, Sarhan AAD, Hamdi M (2013) An investigation of optimum SiO2 nanolubrication parameters in end milling of aerospace Al6061-T6 alloy. Int J Adv Manuf Technol 67(1–4):833–849

    Google Scholar 

  45. Xu DC, Feng PF, Li WB, Ma Y, Liu B (2014) Research on chip formation parameters of aluminum alloy 6061-T6 based on high-speed orthogonal cutting model. Int J Adv Manuf Technol 72(5–8):955–962

    Google Scholar 

  46. Sun J, Guo YB (2008) A new multi-view approach to characterize 3D chip morphology and properties in end milling titanium Ti–6Al–4V. Int J Mach Tools Manuf 48(12–13):1486–1494

    Google Scholar 

  47. Velasquez JDP, Bolle B, Chevrier P, Geandier G, Tidu A (2007) Metallurgical study on chips obtained by high speed machining of a Ti–6 wt.%Al–4 wt.%V alloy. Mater Sci Eng A 452-453:469–474

    Google Scholar 

  48. Ulutan D, Ozel T (2011) Machining induced surface integrity in titanium and nickel alloys: A review. Int J Mach Tools Manuf 51(3):250–280

    Google Scholar 

  49. Wang YG, Li CH, Zhang YB, Li BK, Yang M, Zhang XP, Guo SM, Liu GT, Zhai MG (2017) Comparative evaluation of the lubricating properties of vegetable-oil-based nanofluids between frictional test and grinding experiment. J Manuf Process 26:94–104

    Google Scholar 

  50. Zhang YB, Li CH, Yang M, Jia DZ, Wang YG, Li BK, Hou YL, Zhang NQ, Wu QD (2016) Experimental evaluation of cooling performance by friction coefficient and specific friction energy in nanofluid minimum quantity lubrication grinding with different types of vegetable oil. J Clean Prod 139:685–705

    Google Scholar 

  51. Li BK, Li CH, Zhang YB, Wang YG, Jia DZ, Yang M, Zhang NQ, Wu QD, Han ZG, Sun K (2017) Heat transfer performance of MQL grinding with different nanofluids for Ni-based alloys using vegetable oil. J Clean Prod 154:1–11

    Google Scholar 

  52. Sen B, Mia M, Gupta MK, Rahman MA, Mandal UK, Mondal SP (2019) Influence of Al2O3 and palm oil–mixed nano-fluid on machining performances of inconel-690: if-then rules–based fis model in eco-benign milling. Int J Adv Manuf Technol 103:9–12

  53. Martin JM, Ohmae N (2008) Nanolubricants, Wiley, Manhattan

  54. Kato H, Komai K (2007) Tribofilm formation and mild wear by tribo-sintering of nanometer-sized oxide particles on rubbing steel surfaces. Wear 262(1–2):36–41

    Google Scholar 

  55. Huang HD (2006) An investigation on tribological properties of graphite nanosheets as oil additive. Wear 261(2):140–144

    Google Scholar 

  56. Ding AP (2001) On uses and manufacturing method of “Nano alumina”. NON-FERROUS SMELTING 30(3):6–9

    Google Scholar 

  57. Wang YG, Li CH, Zhang YB, Li BK, Yang M, Zhang XP, Guo SM, Liu GT (2016) Experimental evaluation of the lubrication properties of the wheel/workpiece interface in MQL grinding with different nanofluids. Tribol Int 99:198–210

    Google Scholar 

  58. Zhang YB, Li CH, Jia DZ, Li BK, Wang YG, Yang M, Hou YL, Zhang XW (2016) Experimental study on the effect of nanoparticle concentration on the lubricating property of Nanofluids for MQL grinding of Ni-based alloy. J Mater Process Technol 232:100–115

    Google Scholar 

  59. Demas NG, Timofeeva EV, Routbort JL, Fenske GR (2012) Tribological effects of BN and MoS2 nanoparticles added to polyalphaolefin oil in piston skirt/cylinder liner tests. Tribol Lett 47(1):91–102

    Google Scholar 

  60. Chinnam J, Das D, Vajjha R, Satti J (2015) Measurements of the contact angle of nanofluids and development of a new correlation. International Communications in Heat and Mass Transfer 62:1–12

    Google Scholar 

  61. Rapoport L, Nepomnyashchy O, Lapsker I, Verdyan A, Moshkovich A, Feldman Y, Tenne R (2005) Behavior of fullerene-like WS {sub}2 nanoparticles under severe. Wear: an international journal on the science and Technology of Friction, lubrication and Wear 259(1):703–707

    Google Scholar 

  62. Rapoport L, Leshchinsky V, Lvovsky M, Nepomnyashchy O, Volovik Y, Tenne R (2002) Mechanism of friction of fullerenes. Industrial Lubrication and Tribology 54(4):171–176

    Google Scholar 

Download references

Funding

This research was financially supported by the following organizations: The National Natural Science Foundation of China (51575290 and 51806112), the Major Research Project of Shandong Province (2017GGX30135 and 2018GGX103044), and the Shandong Provincial Natural Science Foundation of China (ZR2017PEE002 and ZR2017PEE011).

Author information

Author notes

  1. Zhenjing Duan and Qingan Yin contributed equally to this work.

Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, 266520, China

    Zhenjing Duan, Changhe Li, Yanbin Zhang & Min Yang

  2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Qingan Yin & Zhanqiang Liu

  3. School of Mechanical and Electrical Engineering, Qingdao Binhai University, Qingdao, 266555, China

    Lan Dong & Xiufang Bai

  4. School of Mechanical Engineering, Inner Mongolia University for Nationalities, Tongliao, 028000, China

    Dongzhou Jia

  5. Department of Biomedical Engineering, University of Southern California, Los Angeles, CA, 90089-1111, USA

    Runze Li

Authors
  1. Zhenjing Duan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Qingan Yin
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Changhe Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Lan Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Xiufang Bai
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Yanbin Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Min Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Dongzhou Jia
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Runze Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  10. Zhanqiang Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Changhe Li or Lan Dong.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Highlights

• NMQL milling experiments of cottonseed oil–based Al2O3 nanofluids of different mass fractions (0 wt%, 0.2 wt%, 0.5 wt%, 1 wt%, 1.5 wt%, 2 wt%) were carried out with 45 steel.

• The lubrication properties of cottonseed oil–based Al2O3 nanofluids of different mass fractions milling 45 steel were compared.

• The surface morphology of workpiece and debris was analyzed.

• The lubricating mechanisms of cottonseed oil and antiwear and antifriction mechanism of Al2O3 nanoparticles as lubricant additives were analyzed.

• The optimum mass concentration of Al2O3 nanofluids (0.5 wt%) with cottonseed oil as the base oil was obtained.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Duan, Z., Yin, Q., Li, C. et al. Milling force and surface morphology of 45 steel under different Al2O3 nanofluid concentrations. Int J Adv Manuf Technol 107, 1277–1296 (2020). https://doi.org/10.1007/s00170-020-04969-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-04969-9

Keywords

Search

Navigation