Vol. 27 No. 2 2025 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases.
OBRABOTKAMETALLOV Vol. 27 No. 2 2025 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Aff airs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, V.P. Larionov Institute of the Physical-Technical Problems of the North of the Siberian Branch of the RAS, Yakutsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 27 No. 2 2025 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Sundukov S.K., Nigmetzyanov R.I., Prikhodko V.M., Fatyukhin D.S., Koldyushov V.K. Comparison of ultrasonic surface treatment methods applied to additively manufactured Ti-6Al-4V alloy................................................................ 6 Kate N., Kulkarni A.P., Dama Y.B. A comparative evaluation of friction and wear in alternative materials for brake friction composites............................................................................................................................................................... 29 Naumov S.V., Panov D.O., Sokolovsky V.S., Chernichenko R.S., Salishchev G.A., Belinin D.S., Lukianov V.V. Microstructure and mechanical properties of Ti2AlNb-based alloy weld joints as a function of gas tungsten arc welding parameters............................................................................................................................................................................. 43 Jatti V.S., Singarajan V., SaiyathibrahimA., Jatti V.S., KrishnanM.R., Jatti S.V. Enhancement of EDM performance for NiTi, NiCu, and BeCu alloys using a multi-criteria approach based on utility function................................................ 57 Stelmakov V.A., Gimadeev M.R., Nikitenko A.V. Ensuring hole shape accuracy in fi nish machining using boring...... 89 EQUIPMENT. INSTRUMENTS Patil N., Agarwal S., Kulkarni A.P., Saraf A., Rane M., Dama Y.B. Experimental investigation of graphene oxide-based nano cutting fl uid in drilling of aluminum matrix composite reinforced with SiC particles under nano-MQL conditions............................................................................................................................................................................. 103 Gimadeev M.R., Stelmakov V.A., Nikitenko A.V., Uliskov M.V. Prediction of surface roughness in milling with a ball end tool using an artifi cial neural network................................................................................................................. 126 Osipovich K.O., Sidorov E.A., Chumaevskii A.V., Nikonov S.N., Kolubaev E.A. Manufacturing conditions of bimetallic samples based on iron and copper alloys by wire-feed electron beam additive manufacturing......................... 142 Babaev A.S., Savchenko N.L., Kozlov V.N., Semenov A.R., Grigoriev M.V. Performance of Y-TZP-Al2O3 composite ceramics in dry high-speed turning of thermally hardened steel 0.4 C-Cr (AISI 5135)...................................................... 159 MATERIAL SCIENCE Sokolov R.A., Muratov K.R., Mamadaliev R.A. Morphological changes of deformed structural steel surface in corrosive environment......................................................................................................................................................... 174 Chernichenko R.S., Panov D.O., Naumov S.V., Kudryavtsev E.A., Salishchev G.A., Pertsev A.S. Eff ect of heterogeneous structure on mechanical behavior of austenitic stainless steel subjected to novel thermomechanical processing............................................................................................................................................................................. 189 Panov D.O., Chernichenko R.S., Naumov S.V., Kudryavtsev E.A., Salishchev G.A., Pertsev A.S. Eff ect of cold radial forging on structure, texture and mechanical properties of lightweight austenitic steel................................................ 206 Deshpande A., Kulkarni A.P., Anerao P., Deshpande L., Somatkar A. Integrated numerical and experimental investigation of tribological performance of PTFE based composite material.................................................................... 219 Vorontsov A.V., Panfi lov A.O., Nikolaeva A.V., Cheremnov A.V., Knyazhev E.O. Eff ect of impact processing on the structure and properties of nickel alloy ZhS6U produced by casting and electron beam additive manufacturing........ 238 Misochenko A.A. Martensitic transformations in TiNi-based alloys during rolling with pulsed current........................... 255 EDITORIALMATERIALS 270 FOUNDERS MATERIALS 279 CONTENTS
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 7 2 5 Experimental investigation of graphene oxide-based nano cutting fluid in drilling of aluminum matrix composite reinforced with SiC particles under nano-MQL conditions Nilesh Patil 1, a, Sachin Agarwal 2, b, Atul Kulkarni 3, c, *, Atul Saraf 4, d, Milind Rane 3, e, Yogiraj Dama 5, f 1 Maharashtra Institute of Technology, Aurangabad-431010, Maharashtra, India 2 Deogiri Institute of engineering and management studies, Aurangabad, 431005, India 3 Vishwakarma Institute of Technology, Pune, Maharashtra, 411037, India 4 Sardar Vallabhai National Institute of Technology, Surat, 395007, India 5 Dr. Babasaheb Ambedkar Technological University, Lonere, Raigad, Maharashtra, 402103, India a https://orcid.org/0000-0002-4884-4267, nileshgpatil@rediffmail.com; b https://orcid.org/0000-0003-4582-1745, sachinagarwal@dietms.org; c https://orcid.org/0000-0002-6452-6349, atul.kulkarni@vit.edu; d https://orcid.org/0000-0003-4776-6874, atul.saraf001@gmail.com; e https://orcid.org/0000-0001-5829-5305, milind.rane@vit.edu; f https://orcid.org/0009-0008-5404-4347, yogirajdama@dbatu.ac.in Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2025 vol. 27 no. 2 pp. 103–125 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2025-27.2-103-125 ART I CLE I NFO Article history: Received: 12 January 2025 Revised: 12 February 2025 Accepted: 17 March 2025 Available online: 15 June 2025 Keywords: Nano cutting fluid NMQL Graphene oxide Circularity Burr height Empirical modeling ABSTRACT Introduction. Minimum Quantity Lubrication (MQL) is effectively employed as suitable cooling strategy. However, compared to flood cooling, which is widely used in the industry, MQL is characterized by a lower heat dissipation capacity. While thermal shock is reported in flood cooling, the use of MQL ensures a smoother chip removal and reduces the risk of thermal stress. Research methods. Within the scope of this study, experimental investigations were carried out on drilling of aluminum matrix composite (MMC) reinforced with silicon carbide (Al-SiC MMC) using AlCrN PVD-coated drills (drill diameter 8 mm). MMC samples were manufactured with varying volume fractions of SiC (10–30%). The aim of the experiments was to study the influence of non-edible vegetable oil with the addition of graphene oxide (used as a cutting fluid) on the drilling process of AlSiC MMC. The cutting speed (30–150 m/min), feed rate (0.05–0.25 mm/rev), volume fraction of SiC (10–30%), and MQL flow rate (60–180 ml/h) were selected as input process parameters. Their response parameters were cutting force, torque, surface roughness, hole circularity, and burr height during high-speed drilling of MMC. The undi (Calophyllum inophyllum) oil parameters were determined in accordance with the ASTM 6751 standard. The surface morphology and elemental analysis of graphene oxide were investigated using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDAX). The purpose of the work. The use of nano-cutting fluid in combination with MQL is one of the promising approaches for further improving the characteristics of MQL, especially when drilling difficult-to-machine materials. The introduction of nanomaterials into MQL contributes to reducing friction at the tool-chip interface, which leads to a decrease in cutting temperature. These methods facilitate the machining of lightweight and difficult-to-machine materials, in particular, aluminum-based metal matrix composites (MMCs), which are widely used in the automotive and aerospace industries. Results and Discussion. It was found that the use of graphene oxide nanoparticles dispersed in non-edible undi (Calophyllum inophyllum) oil represents a promising alternative to traditional cutting fluids in drilling MMC. The aim of the study was to develop semi-empirical models for predicting surface roughness and temperature for various compositions of MMC. Increased cutting efficiency is achieved by precisely determining the temperature in the machining zone. However, the practical determination of the cutting temperature in each specific case involves significant labor and financial costs. It was additionally found that graphene oxide nanoparticles mixed with nonedible undi (Calophyllum inophyllum) oil represent an effective alternative to traditional cutting fluids in drilling MMCs. The present work develops a comprehensive empirical formula for predicting the theoretical temperature and surface roughness. It was found that the majority of the power input into the machining process is transformed into thermal energy. For citation: Patil N., Agarwal S., Kulkarni A.P., Saraf A., Rane M., Dama Y.B. Experimental investigation of graphene oxide-based nano cutting fluid in drilling of aluminum matrix composite reinforced with SiC particles under nano-MQL conditions. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 2, pp. 103–125. DOI: 10.17212/19946309-2025-27.2-103-125. (In Russian). ______ * Corresponding author Kulkarni Atul P., Professor Vishwakarma Institute of Technology, Pune, Maharashtra, 411037, India Tel.: 91-2026950419, e-mail: atul.kulkarni@vit.edu
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 7 No. 2 2025 List of symbols f Feed rate (mm/rev) Vc Cutting speed (m/min) Q Flow Rate (ml/hr) Vf SiC Volume Fraction (%) Fx Thrust force (N) T Torque (Nm) Ra Surface roughness (µm) Bh Bur height (mm) Cr Circularity (mm) RSM Response surface methodology CCD Central composite design Introduction The main purpose of cutting fluid is to provide cooling and lubrication effects in the machining zone. A cutting fluid may reduce tool wear, enhance surface finish, and also contribute to evacuating chips from the machining zone, which supports sustainable machining. However, due to ecological concerns and increasing regulations over contamination and pollution, the demand for renewable and eco-friendly cutting fluids is increasing [1‑4]. The “term sustainable manufacturing” refers to the creation of products using non-polluting methods and systems, while also preserving energy and natural resources. Such a model must be financially viable, harmless, and healthful for operators [4‑5]. In cutting of few difficult-to-cut materials, the heat generation produces other concerns such as thermal cracks and dimensional inaccuracy. Heat dispersal in machines is usually attained by the application of cutting fluids. However, the rising concern has led governments and allied organizations to impose stringent rules and guidelines to oversee the use, recycling, and discarding of cutting fluids. Hence, the industry aims at switching from wet cooling to more economical yet environmentally friendly alternatives. These options include MQL, environmentally friendly cutting fluids, nano-cutting fluids, dry cutting, etc. [6‑10]. The MQL method is an attractive alternative in which a very small quantity of cutting fluid is applied to the machining zone through a nozzle. In MQL, cutting fluid is delivered to the machining area drop by drop or as mist. When applied as mist, cutting fluid is atomized by a jet of air, and the mist is directed at the cutting zone. Extensive research has been conducted on MQL techniques [11‑12]. Many researchers have used vegetable oil along with MQL because vegetable oil is a potential source of environmentally favorable cutting fluid due to a combination of biodegradability, renewability, and excellent lubrication performance [13‑15]. Recently, non-edible oils used in cutting processes have performed better than traditional machining oils owing to their high lubricity, which creates a strong intermolecular interface on the workpiece. Nonedible oils such as Neem oil, Karanja oil, Jatropha oil, Castor oil, and Cotton seed oil have been researched and found to be good alternatives to conventional oils in terms of functionality [16‑19]. For example, Al2O3 nanoparticles of 20 nm size were used in soybean oil with a volume fraction of 1.5 % in base oil. Trials show that NMQL provides less friction power at tool-chip and tool-workpiece interfaces due to the rolling effect of nanoparticles and superior cooling performance. In addition, nano-fluid MQL effectively removes chips and burrs to improve the surface quality of holes and also increases tool life by achieving the lowest tool wear [20‑22].
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 7 2 5 Sodavadia and Makwana [23] investigated the application of nano boric acid solid lubricant suspensions in coconut oil during turning of AISI 304 austenitic stainless steel with a carbide tool. Nano boric acid solid lubricants of 50 nm particle size were suspended in coconut oil, the base lubricant. The variation of average tool flank wear, surface roughness of the machined surface, and cutting tool temperature with cutting speed and feed rate were identified with nano solid lubricant suspensions in coconut oil. It has been observed from past literature that the use of nanoparticles in machining, especially drilling, proved beneficial due to their significant lubricating and cooling effects. Many researchers have used different nanoparticles with vegetable and conventional cutting fluids; however, no research has yet been reported on using graphene oxide nanoparticles in non-edible vegetable oil like Undi oil [23‑25]. Graphene oxide is a recent material produced from synthetic graphite powder. It has excellent mechanical and thermal properties and is used in many fields such as solar cells, touch screens, and biosensors. One of the exceptional properties of graphene oxide is its superior thermal conductivity, which is as high as 5,800 W/m·K, making graphene oxide particles effective heat transfer channels that can be used as cutting fluids in difficult-to-cut materials such as MMCs [26, 27]. The purpose of this research is to study nano-cutting fluid with the minimum quantity lubrication (MQL) method for automotive and aerospace applications. In the current study, graphene oxide particles have been dispersed in Undi oil. To investigate the influence of graphene oxide nanoparticles in drilling MMC under different cooling conditions, performance was measured in terms of thrust force, torque, surface roughness, circularity, and burr height. The study aims to understand the impact of adding nanomaterials to cutting fluid on the tool-chip interaction surface and on lowering cutting temperature. The focus is on machining lightweight and hard-to-machine materials, such as aluminum-based metal matrix composites (MMCs). CNC machine, MQL system, cutting tool, and surface roughness tester facilities available at the Mechanical Engineering Department of VIIT, Pune, Maharashtra, India, were used for the research work. Investigation Technique Aluminium metal matrix composites (AMCs) are potential materials for different applications due to their superior physical and mechanical properties. Reinforcements in the metallic matrix improve stiffness, specific strength, and wear properties compared to conventional materials. Aluminium MMCs are commonly used in aircraft, aerospace, automotive, and various other fields. However, these materials are usually regarded as exceptionally difficult to cut because of the abrasive nature of the reinforcement particulates (Table 1). Hence, aluminum metal matrix composites reinforced with SiC particles have been selected as the workpiece material for this study. Table1 shows the properties of the machined materials used in this experimental investigation. SEM micrograph of Al-SiC MMC is shown in Fig. 1 at 300× magnification. Fig. 2, a and b show the Al-SiC MMC plate and PVD-coated cemented carbide drill bit, respectively. Ta b l e 1 Properties of the machined materials Workpiece Properties Thermal coefficient of expansion (K−1) Specific heat, (J/kg∙K) Thermal conductivity, (W/m∙K) Density, (kg/m3) Melting point, (K) Al/SiCp/10% 20.7 879 156 2.710 828 Al/SiCp/20% 17.46 837 150 2.765 828 Al/SiCp/30% 14.58 795 144 2.798 828
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 7 No. 2 2025 The nomenclature of the PVD-coated carbide drill used in this research study was SD1105A-0680-04308R1 with a point angle of 140° and 8 mm diameter. This drill was coated with polished AlCrN coating. The uniqueness of AlCrN coating is that it offers high abrasion resistance, high hardness, good adhesion, and good chip evacuation [27]. A vertical machining center (BMV 60+ series) was selected for the drilling operation, ensuring highly precise and accurate quality performance with high speed and feed rate. Fig. 3, a shows the spike wireless force sensor with tool holder. This wireless force sensor tool holder was used to measure the generated force, torque, and bending moment directly at the tool holder, and the captured data were transmitted to the receiver through a wireless network. The corresponding software processes the data and provides the desired output. As shown in Fig. 3, b, the MQL system used in this experiment has two inlet tubes and one discharge pipe that combine in the mixing chamber. One inlet tube was attached to an air compressor, while the other was inserted into a container containing a newly formulated nano-cutting fluid. Based on the air pressure, the oil from the container was pulled out and supplied through the discharge tubes in the form of mist. For various combinations of process parameters, drilling tests were carried out. The use of Undi oil in metal cutting as a cutting fluid may lead to multiple environmental and agricultural advantages; hence, this oil was selected for experimentation. Undi oil has high survival potential in the environment, remaining stable for up to 50 years. It does not compete with food crops. It serves as a windbreaker at the coast where it can reduce abrasion, protect crops, and offer ecotourism benefits. It has higher oil yield, viscosity, and flash point than generally used non-edible vegetable oils such as Jatropha, Neem, Rubber, a b c Fig. 1. SEM micrographs of Al/SiC MMC at SiC volume fractions of: a – 10%; b – 20%; c – 30% a b Fig. 2. Al-SiC MMC workpiece material (a) and AlCrN (PVD) сoated drill (b)
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 7 2 5 a b Fig. 3. Wireless tool holder (a) and MQL setup (b) Cotton, Pongamia pinnata, etc. Characterization of Undi oil has been done, and its properties are tabulated in Table 2 as per ASTM D6751. Graphene oxide was used as a nanoparticle to mix with Undi oil to generate the base fluid/coolant. FESEM was used to reveal the structure of graphene oxide, as shown in Fig. 4, a, which indicates that the size of the graphene oxide sheets is approximately 10 nm. In addition, Fig. 4, b shows EDAX plots of graphene oxide, which provide evidence of the presence of C and O ions with the proper ratio, confirming the desired stoichiometric composition. The properties of graphene oxide are given in Table 3. In order to make nano-cutting fluid, 10 nm-sized graphene oxide nanoparticles were selected due to their potential applications and superior properties. To prepare the nano cutting fluid, four grams of graphene oxide nanoparticles were mixed with 200 ml of Undi oil as the base fluid to prepare the sample. The graphene oxide nanoparticles and Undi oil were mixed in a proportion of 2 w/v % and continuously stirred using a magnetic stirrer for about 24 hours, followed by ultrasonication for 2 hours, as shown in Fig. 5. Ta b l e 2 Properties of Undi Oil Test Description Density (g/c3) Flash point (°С) Fire point (°С) Viscosity (Cst) Thermal conductivity (W/m K) Ph range ASTM 6751 D1148 D93 D93 D445 D2709 – Undi Oil 0.91 152 162 38.16 164–168 6.7 a b Fig. 4. FESEM image of graphene oxide (a) and EDAX plots of graphene oxide (b)
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 7 No. 2 2025 Ta b l e 3 Properties of graphene oxide Specifications Purity Thickness Lateral Dimension Number of Layer Surface Area Values > 99% 1–5 nm 5–10 µm Upon the average 4–8 210 m2/g Ta b l e 4 Machining parameters and levels Levels −2 −1 0 +1 +2 Cutting speed (Vc) (m/min) 30 60 90 120 150 Feed rate (f) (mm/rev) 0.05 0.1 0.15 0.2 0.25 Flow rate (Q) (ml/hr) 60 90 120 150 180 SiC vol. fraction (Vf) (%) 10 10 20 30 30 Fig. 5. Ultrasonication process for preparation of nano cutting fluid Response surface methodology (RSM) was used for the design of experiments. The objective was to optimize performance measures (responses) influenced by several independent variables commonly known as process parameters. Cutting speed, feed rate, flow rate, and SiC volume fraction were selected as process parameters, while thrust force, torque, surface roughness, burr height, and circularity were chosen as responses. Process parameters and their levels were chosen based on literature review and initial trials. Table 4 shows the process parameters and their levels used in the experiments. Results and Discussion A series of trials were carried out on the VMC machine using various speeds, feed rates, flow rates, and SiC volume fractions. The central composite design (CCD) of the response surface method was used for the main experiments, and the corresponding results are tabulated in Table 5. ANOVA was used, and the validity of the statistical results was measured with F-values and P-values. The reliability of the fitted model is recognized by R². The purpose of the experimental analysis was to determine the significant factors that have the greatest influence on the response variables and to develop a generalized empirical model to
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 7 2 5 Ta b l e 5 Experimental results during NMQL condition Seq. No. Process Parameters Responses Vc f Q Vf Fx T Ra Cr Bh m/min mm/rev ml/h % N N∙m µm mm mm 1 60 0.1 90 10 282.58 0.783 0.806 0.0287 0.0021 2 120 0.1 90 10 324.21 0.882 0.710 0.0178 0.0436 3 60 0.2 90 10 579.48 1.318 1.784 0.0496 0.0022 4 120 0.2 90 10 577.29 1.282 0.687 0.0300 0.0000 5 60 0.1 150 10 882.81 2.579 2.944 0.0427 0.2926 6 120 0.1 150 10 824.56 2.832 1.326 0.1490 0.3922 7 60 0.2 150 10 1166.5 3.076 2.120 0.0971 0.3675 8 120 0.2 150 10 1059.25 3.114 1.651 0.1385 0.2852 9 60 0.1 90 30 656.62 1.781 2.571 0.1949 0.0800 10 120 0.1 90 30 786.55 1.893 0.075 0.2048 0.1350 11 60 0.2 90 30 1276.03 3.054 0.081 0.1991 0.1827 12 120 0.2 90 30 1206.18 2.688 0.084 0.2059 0.1495 13 60 0.1 150 30 1179.84 3.413 0.089 0.1731 0.2583 14 120 0.1 150 30 1228.36 3.196 0.101 0.1880 0.2706 15 60 0.2 150 30 1534.67 4.604 0.084 0.1873 0.3451 16 120 0.2 150 30 1440.98 3.602 0.224 0.2123 0.3165 17 30 0.15 120 20 953.49 4.131 0.671 0.2559 0.4131 18 150 0.15 120 20 1383.82 4.137 0.921 0.1624 0.332 19 90 0.05 120 20 917.38 3.594 0.208 0.0629 0.5020 20 90 0.25 120 20 1353.33 4.558 0.559 0.1678 0.3343 21 90 0.15 60 20 1186.69 4.363 1.907 0.1621 0.4622 22 90 0.15 180 20 1215.34 4.264 1.505 0.1688 0.4703 23 90 0.15 120 10 1025.96 2.91 2.571 0.1064 0.3380 24 90 0.15 120 30 1389.17 4.215 0.369 0.2225 0.4062 25 90 0.15 120 20 1197.34 4.385 2.122 0.2242 0.4340 26 90 0.15 120 20 1229.32 4.299 1.401 0.1498 0.4634 27 90 0.15 120 20 1253.25 4.406 1.535 0.1522 0.4382 28 90 0.15 120 20 1290.29 4.704 1.578 0.1380 0.5263 29 90 0.15 120 20 1284.21 4.862 1.211 0.0891 0.3630 30 90 0.15 120 20 1275.76 4.881 2.091 0.0817 0.3763 31 90 0.15 120 20 1284.96 4.689 0.921 0.0727 0.4222 predict thrust force, torque, surface roughness, burr height, and circularity. RSM explores the relationship between process parameters and responses. Surface plots developed through RSM analyze the effect of process parameters on one response while keeping all other process parameters fixed. The relationship between responses and process parameters was visualized by three-dimensional surface plots. Based on the results, response surface model has been developed for the responses and presented in the equations below. 3386.81 13.4633 11380.1 21.2839 114.253 18.1171 0.021541 x c f c c F V F Q V V F V Q
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 7 No. 2 2025 0.0293687 20.9663 0.148144 c f f f V V F V Q V 2 2 2 2 0.0428178 18744.4 0.0338289 2.17802 c f V F Q V ; (1) 2 2 14.04 0.057358 33.1715 0.0687884 0.758479 0.0672083 5.11806 05 0.000380625 0.026125 0.243875 0.000403542 0.000194778 75.9202 c f c c c f f f c T V F Q V V F e V Q V V F Q F V Q V V F 2 2 0.000144917 0.0164664 f Q V ; (2) 2 2 1.19377 0.00410337 25.6013 0.000873283 0.189131 0.115625 0.000121597 0.000195625 0.0477083 0.352375 0.00132646 0.000215872 118.964 c f c c c f f f c Ra V F Q V V F V Q V V F Q F V Q V V F 2 2 3.69053 0.00138445 ; f Q V (3) 5 2 2 2 0.0466403 0.00409958 1.35925 0.000901806 0.0216226 0.002775 1.39861 10 1.2625 05 0.00183333 05 3.23667 4.92593 06 c f c c f c Cr V F Q V V F V Q e Q V V F e Q 2 0.000124167 f V ; (4) 2 1.59316 0.00839594 2.24223 0.00683264 0.0923996 0.0147708 4.1875 0.000134604 3.11267 c f c c f c Bh V F Q V V F V Q Q V V 2 2 2 6.64562 5.09895 0.00197624 . f F Q V (5) The adequacy of the models has been tested by the correlation coefficient; R² values in the case of thrust force, torque, surface roughness, burr height, and circularity were found to be 0.9610, 0.9423, 0.9733, 0.957, and 0.964 respectively, which shows good agreement between actual readings and predicted values from the model. Thrust is the force of reaction against the drill’s progress into the workpiece. The test data of the thrust forces as a function of cutting parameters in the drilling of the Al-SiC MMC as per DOE were observed and recorded. Drilling is a complex process involving a combination of axial (thrust) force and peripheral (torque) force. It has been reported that the most impact on surface deterioration of the workpiece is caused by the thrust force due to the differential flexural characteristics of the matrix and the fiber reinforcement. Thrust force can be used as a process measure to assess the response of the tool-workpiece interface. Any variation in thrust force can be related to a change in the cutting wedge condition, either by deformation, other tool wear modes, or potential interactions between the tool and the heat-affected workpiece in the machining zone [24].
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 7 2 5 Fig. 6, a shows that minimum Fx is observed at 10 % SiC volume fraction, while maximum occurs at higher SiC volume fractions; similarly, as feed increases, Fx also increases. It has been observed from Fig. 6, b that Fx varies according to Q, with maximum Fx at 150 ml/h and 0.2 mm/rev, while minimum at 90 ml/h and 0.1 mm/rev. Fig. 6, c shows that maximum Fx is observed at 150 ml/hr and 30 % Vf. It has been observed that as Q increases, Fx also increases; a similar trend has been observed for Vf. However, a rapid increase in Fx occurs as Vf increases from 10 to 20 %, while no significant rise is found after 20 % Vf. Fig. 6, a and b depict that as f increases from 0.1 to 0.2 mm/rev, Fx also increases rapidly. These results are in agreement with reports by Gaitonde et al. [11]. Fig. 6, a and c indicate that as Vf increases from 10 to 30 %, Fx also increases rapidly; however, no significant difference has been observed between 20 and 30 % Vf – similar findings were reported by Gaitonde et al. [12]. It has been seen from Fig. 6, b and c that minimum Fx is obtained at low Q (90 ml/hr), while maximum is at high Q (150 ml/hr). a b c Fig. 6. Effect of cutting speed, feed, sic volume fraction and flow rate on thrust force under NMQL conditions Like thrust force, torque also affects the quality of the hole generated. During drilling, the sharp cutting edges over the periphery are often blunt and produce friction by rubbing rather than cutting [18]. The effect of process parameters on torque is shown in Fig. 7. Fig. 7, a indicates that as Vf increases from 10 to 30 %, torque also increases rapidly; however, after 20 % Vf, torque shows a slight decrease. It has also been seen that minimum torque occurs at low feed rate and flow rate combination (90 ml/h and 0.1 mm/rev), while maximum occurs at 150 ml/h and 0.2 mm/rev. In addition, Fig. 7, b shows that as feed increases from 0.1 to 0.2 mm/rev, torque also increases. Surface roughness is an indicator of finely spacedmicro-irregularities on the surface texture, consisting of three parts: roughness, waviness, and form [24]. It evaluates the surface finish to assess surface irregularities of the workpiece due to machining. It is normally determined as the average roughness (Ra), commonly used in the industry. Surface roughness is among the essential aspects of hole quality, where greater surface roughness causes additional wear and fatigue in the material, which directly impacts the production process and cost [21]. It plays a key role in manufacturing and is a major element in assessing machining accuracy [22]. From Fig. 8, a, it has been observed that maximum Ra is seen at 10 % Vf, while it decreases sharply at 30 % Vf. Also, as feed rate increases from 0.1 to 0.2 mm/rev, Ra increases. Fig. 8, b shows that as Q increases from 90 to 150 ml/hr, Ra also increases sharply. Maximum Ra is observed at low Vf and high Q (10 % Vf and 150 ml/h), while minimum at high Vf and high Q. Fig. 8, c shows maximum Ra at 10 %
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 7 No. 2 2025 a b c Fig. 8. Effect of cutting speed, feed rate, SiC volume fraction and flow rate on surface roughness under NMQL conditions a b Fig. 7. Effect of cutting speed, feed, SiC volume fraction and flow rate on torque under NMQL conditions Vf, while it decreases sharply as Vf increases to 30 %. Also, maximum Ra is obtained at 60 m/min, while minimum is obtained at 120 m/min. Fig. 8, a shows that as feed rate increases from 0.1 to 0.2 mm/rev, Ra shows a slightly increasing trend. Lower feed values result in minimum thrust force during drilling, which is one reason for better surface finish at low feed rate [2]. It has been observed from Fig. 8, b that Ra is maximum at 10 % Vf while minimum at 30 % Vf. The increase in Vf decreases Ra, likely caused by increased brittleness and consequent demise of the built-up edge (BUE) in machining composite materials (Gaitonde et al., 2009). Fig. 8, b also shows that as Q increases from 90 to 150 ml/hr, Ra also increases, confirming that at low Q, MQL can provide better Ra in drilling. This is possibly due to reduced BUE formation from the mist action at the tool-workpiece interface. Fig. 8, c shows that as cutting speed changes from 60 m/min to 120 m/min, Ra decreases. This trend can be explained by the fact that as cutting speed increases, cutting temperature rises, leading to material softening and subsequent reduction in Ra. Circularity is defined as the degree of roundness of a circular hole. Circularity defines how close a component should be to a perfect circle. Circularity, often called roundness, is a 2-dimensional tolerance that determines the overall shape of a circle and ensures it is not too oval, rectangular, or irregular [2].
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 7 2 5 It has been observed from Fig. 9, a that minimum circularity (Cr) is obtained at 0.1 mm/rev and 10 % SiC volume fraction, while maximum occurs at 30 % SiC volume fraction and 0.2 mm/rev. Fig. 9, b shows minimum Cr at 10 % SiC volume fraction and maximum at 30 %, with Cr increasing with flow rate (minimum at 90 ml/h, maximum at 150 ml/h). Fig. 9, a shows minimum Cr at 0.1 mm/rev and maximum at 0.2 mm/rev; Cr increases with feed rate, likely due to increased cutting forces. Faster insertion of the drilling tool through the workpiece due to higher feed rate increases hole deformations and vibrations in the cutting tool, resulting in higher circularity errors. Fig. 9, a and b show Cr increases rapidly as Vf changes from 10 to 30 %, with minimum Cr at 10 % and maximum at 30 %. a b Fig. 9. Effect of cutting speed, feed rate, SiC volume fraction and flow rate on circularity under NMQL condition Burr is plastically deformed material produced on the edge of the component during drilling. Burrs form and spread circumferentially as the drill feeds into the workpiece. The size of the exit burr is a performance measure of the drilling process that determines the quality of the finished product. It is essential to minimize burr formation at manufacturing stage by choosing proper drilling process parameters. Fig. 10, a shows that as SiC volume fraction increases from 10 to 20 %, burr height (Bh) increases; however, after 20 % it decreases. As flow rate increases, Bh increases. Maximum Bh is obtained at 20 % Vf and 150 ml/h, while minimum at 10 % Vf and 90 ml/h. Fig. 10, b shows no significant effect of cutting speed and feed on Bh, although maximum burr height is observed at low feed and cutting speed (60 m/min and 0.1 mm/rev). Fig. 10, a shows Bh increases with Q from 90 to 150 ml/h due to excessive fluid and nanoparticles at the workpiece-tool and chip-tool interface, which increases cutting force and ploughing during drilling, thus increasing burr height [21]. Bh increases as Vf changes from 10 to 20 %, but decreases from 20 to 30 %. Fig. 10, b shows no significant effect of cutting speed on Bh, although a slight increase at 60 m/min is observed. Comparison of MQL and NMQL conditions at different cutting speeds and SiC volume fractions was conducted to understand the effect of graphene oxide nanoparticles mixed with Undi oil. Fig. 11 shows that at 10 % SiC volume fraction, MQL gives better results compared to NMQL, while NMQL performs equally or better at 20 and 30 % SiC volume fractions. This is because graphene oxide nanoparticles have a b Fig. 10. Effect of cutting speed, feed rate, SiC volume fraction and flow rate on burr height under NMQL condition
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 7 No. 2 2025 Fig. 11. Comparison of variation of thrust force (Fx) with cutting speed (Vc) and SiC volume fraction in drilling Fig. 12. Comparison of variation of torque (T) with feed rate (f) and SiC volume fraction in drilling exceptional thermal conductivity and high lubrication capacity. Graphene oxide nanoparticles mixed with Undi oil as an additive can significantly increase thermal conductivity and lubrication, leading to reduced cutting forces. NMQL significantly reduces thrust forces compared to MQL due to friction reduction at the contact face caused by the rolling effect of nanoparticles and superior cooling performance [16]. Overall, thrust force is minimum at lower SiC volume fraction (10 %) and maximum at higher volume fraction (30 %). Fig. 12 shows that at 10 % SiC volume fraction, both MQL and NMQL give similar torque results. At 20 % SiC, MQL gives lower torque values. At 30 % SiC, NMQL performs better; this torque reduction may be due to enhanced lubricity from sliding graphene oxide particles in the cutting fluid [17]. Maximum torque values are obtained at intermediate cutting speeds. Torque reduction is attributed to improved lubrication and cooling by the nanofluid. Lower torque during NMQL drilling is due to enhanced thermal conductivity and heat transfer coefficient [19]. Fig. 13 shows NMQL produces less burr height compared to MQL. High temperatures generated during MQL increase material ductility, producing larger burrs. Overall, burr height is minimum at 10 % Vf and maximum at 20 %. During drilling, heat commonly accumulates at the final machining step due to BUE formation as the tool penetrates deeper, affecting exit hole surface quality. NMQL minimizes burr formation due to enhanced heat transfer in the cutting zone. BUE formation and tool wear are also reduced, leading to less burr [16]. Burr height correlates with thrust force and torque, which decrease greatly under NMQL. Fig. 14 shows that at 30 m/min cutting speed, MQL performs better, but at other speeds NMQL gives better results for 10, 20, and 30 % SiC volume fractions. Under NMQL, nanocutting fluid reduces temperature more than MQL due to improved thermal conductivity from graphene oxide nanoparticles. Combined lubricating action reduces friction between chip and tool-workpiece interface, aiding smooth sliding. Overall circularity is minimum at 10 % and maximum at 30 % SiC volume fraction [20].
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 7 2 5 Fig. 13. Comparison of variation of burr height (Bh) with feed (f) and SiC volume fraction in drilling Fig. 14. Comparison of variation of circularity (mm) with cutting speed (Vc) and SiC volume fraction in drilling Fig. 15 shows that at low cutting speeds, MQL performs better, while at higher speeds NMQL gives better results. At high speeds, lack of heat transfer degrades surface quality due to retained heat. Graphene oxide nanofluids, with higher thermal conductivity, improve heat transfer, reduce friction and temperature, and yield better surface finish. High temperature is eliminated from the machining area due to high thermal conductivity. The ball bearing effect of nanoparticles under MQL decreases friction and provides superior cooling and lubrication at the tool-chip interface, reducing tool wear and surface roughness [4]. In this study, the main wear mechanism was abrasion, although adhesion wear was also observed. Different wear types may occur simultaneously or one may dominate due to friction between tool and workpiece. SEM results in Fig. 16, a show the drill tool micrograph after NMQL cooling, and Fig. 16, b shows Fig. 15. Comparison of variation of surface roughness (Ra) with cutting speed (Vc) and SiC volume fraction in drilling
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 7 No. 2 2025 an enlarged view. Ridge formation marks are observed on the tool flank face. Due to the high hardness of the tungsten carbide drill tool, abrasion wear in the form of ridges is common for cemented carbide tools. Ridge formation is also caused by the rolling of broken hard carbide tool fragments and nano graphene particles in the cutting zone. During MMC drilling, composite particle fragments adhere to the tool forming BUE. Coating was worn away from the substrate during drilling due to abrasion and adhesion wear. Builtup edge formation and abrasion marks are clearly visible on the SEM micrograph along with prominent ridge formation. Conclusions In this experimental investigation, a series of drilling experiments were conducted on MMCs with a PVD-coated tool to study the effects of nano-graphene oxide suspended cutting fluid on thrust force, torque, surface finish, burr height, and circularity. Based on the study, the following conclusions have been drawn: 1. This investigation confirms that environmentally friendly methods, particularly NMQL, can be effectively applied without compromising process results during industrial applications such as drilling MMCs with PVD-coated carbide drills. 2. Graphene oxide nanoparticles mixed with non-edible Undi oil are a viable alternative to conventional cutting fluids in drilling MMCs. 3. NMQL provides better hole quality compared to MQL due to the combined lubricating action of nanoparticles and Undi oil, which effectively enters interface regions and decreases friction between chip and tool-workpiece interface, resulting in smoother sliding and improved circularity. At high cutting speeds, circularity is maximum; at low speeds, circularity is minimum. Similarly, circularity increases as SiC volume fraction increases from 10 to 30 %. 4. Mathematical models describing the relationships between responses and process parameters were developed using RSM. Linear regression models best describe these relationships. 5. Burr height increases sharply as SiC volume fraction changes from 10 to 20 %, then shows a slight decrease at 30 %. 6. Graphene oxide nanofluids, due to their higher thermal conductivity, improve heat transfer and thus provide better surface finish at high cutting speeds compared to MQL. 7. NMQL produces less burr height compared to MQL because high temperatures during MQL increase material ductility, causing greater burr formation. 8. At low cutting speeds, MQL yields better surface finish, while at higher cutting speeds, NMQL performs better due to higher thermal conductivity reducing friction and temperature. 9. Lower torque values are observed during NMQL compared to MQL, attributed to better lubricity from graphene oxide particles. Maximum torque occurs at intermediate cutting speeds. a b Fig. 16. Micrographs of drill tool used in NMQL condition after experimentation
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