Vol. 26 No. 4 2024 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. 26 No. 4 2024 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. 26 No. 4 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Manikanta J.E., Ambhore N., Shamkuwar S., Gurajala N.K., Dakarapu S.R. Investigation of vegetable-based hybrid nanofl uids on machining performance in MQL turning........................................................................................... 6 Dama Y.B., Jogi B.F., Pawade R., Kulkarni A.P. Impact of print orientation on wear behavior in FDM printed PLA Biomaterial: Study for hip-joint implant...................................................................................................................... 19 GrinenkoA.V., ChumaevskyA.V., Sidorov E.A., Utyaganova V.R.,AmirovA.I., Kolubaev E.A. Geometry distortion, edge oxidation, structural changes and cut surface morphology of 100mm thick sheet product made of aluminum, copper and titanium alloys during reverse polarity plasma cutting...................................................................................... 41 Somatkar A., Dwivedi R., Chinchanikar S. Comparative evaluation of roller burnishing of Al6061-T6 alloy under dry and nanofl uid minimum quantity lubrication conditions............................................................................................... 57 Karlina Yu.I., Konyukhov V.Yu., Oparina T.A. Assessment of the quality and mechanical properties of metal layers from low-carbon steel obtained by the WAAM method with the use of additional using additional mechanical and ultrasonic processing..................................................................................................................................................... 75 EQUIPMENT. INSTRUMENTS Yusubov N.D., Abbasova H.M. Systematics of multi-tool setup on lathe group machines............................................... 92 Toshov J.B., Fozilov D.M., Yelemessov K.K., Ruziev U.N., Abdullayev D.N., Baskanbayeva D.D., Bekirova L.R. Increasing the durability of drill bit teeth by changing its manufacturing technology......................................................... 112 Pospelov I.D. Investigation of the distribution of normal contact stresses in deformation zone during hot rolling of strips made of structural low-alloy steels to increase the resistance of working rolls..................................................... 125 Ablyaz T.R., Blokhin V.B., Shlykov E.S., Muratov K.R., Osinnikov I.V. Manufacturing of tool electrodes with optimized confi guration for copy-piercing electrical discharge machining by rapid prototyping method.......................... 138 MATERIAL SCIENCE Shubert A.V., Konovalov S.V., Panchenko I.A. A review of research on high-entropy alloys, its properties, methods of creation and application.................................................................................................................................................. 153 Syusyuka E.N., Amineva E.H., Kabirov Yu.V., Prutsakova N.V. Analysis of changes in the microstructure of compression rings of an auxiliary marine engine.......................................................................................................... 180 Dudareva A.A., Bushueva E.G., Tyurin A.G., Domarov E.V., Nasennik I.E., Shikalov V.S., Skorokhod K.A., Legkodymov A.A. The eff ect of hot plastic deformation on the structure and properties of surface-modifi ed layers after non-vacuum electron beam surfacing of a powder mixture of composition 10Cr-30B on steel 0.12 C-18 Cr-9 Ni-Ti............................................................................................................................................................................. 192 Boltrushevich A.E., Martyushev N.V., Kozlov V.N., Kuznetsova Yu.S. Structure of Inconel 625 alloy blanks obtained by electric arc surfacing and electron beam surfacing........................................................................................... 206 Sablina T.Y., Panchenko M.Yu., Zyatikov I.A., Puchikin A.V., Konovalov I.N., Panchenko Yu.N. Study of surface hydrophilicity of metallic materials modifi ed by ultraviolet laser radiation........................................................................ 218 EDITORIALMATERIALS 234 FOUNDERS MATERIALS 243 CONTENTS
OBRABOTKAMETALLOV Vol. 26 No. 4 2024 TECHNOLOGY Investigation of vegetable-based hybrid nanofl uids on machining performance in MQL turning Javvadi Eswara Manikanta 1, a, Nitin Ambhore 2, b, *, Sonal Shamkuwar 3, c, Naveen Kumar Gurajala 4, d, Santha Rao Dakarapu 5, e 1 Department of Mechanical Engineering, Shri Vishnu Engineering College for Women (A), Bhimavaram, Andhra Pradesh, 534202, India 2 Department of Mechanical Engineering, Vishwakarma Institute of Technology, SPPU, Maharashtra, Pune 411037, India 3 Department of Mechanical Engineering, Vishwakarma Institute of Information Technology, SPPU, Maharashtra, Pune 411048, India 4 Department of Mechanical Engineering, CMR College of Engineering and Technology, Hyderabad, Telangana, 501401, India 5 Department of Mechanical Engineering, Visakha Institute of Engineering and Technology, Narava, Visakhapatnam, 530027, India a https://orcid.org/0000-0002-0881-4899, manijem66@gmail.com; b https://orcid.org/0000-0001-8468-8057, nitin.ambhore@viit.ac.in; c https://orcid.org/0000-0001-7633-0813, sonal.shamkuwar@viit.ac.in; d https://orcid.org/0000-0003-0829-7622, naveenkumargurrijala84@gmail.com; e https://orcid.org/0000-0001-7679-7448, dsantharao@gmail.com 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. 2024 vol. 26 no. 4 pp. 6–18 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.4-6-18 ART I CLE I NFO Article history: Received: 07 August 2024 Revised: 21 August 2024 Accepted: 17 September 2024 Available online: 15 December 2024 Keywords: Nanofl uid Lubrication Machining Performance Turning ABSTRACT Introduction. Vegetable-based hybrid nanofl uids are increasingly important in the context of Minimum Quantity Lubrication (MQL) turning due to its enhanced lubrication properties and environmental benefi ts. These nanofl uids, which typically combine vegetable oils with nanoparticles like graphite or titanium dioxide, improve machining performance by reducing friction and cutting forces, leading to better surface fi nish and tool life. The purpose of the work. Coated carbide tools are widely used for machining SS 304 stainless steel due to its wear resistance and high temperature resistance. The purpose of the current work is to evaluate the machining performance of SS 304 steel under diff erent concentrations of hybrid nanofl uids. The methods of investigation. In this study, an attempt was made to use copper oxide/aluminum oxide (CuO/Al2O3) hybrid nanoparticles mixed with corn oil. A total of six hybrid cutting fl uids with 100 ml volume and diff erent mass concentration (0.4 %, 0.8 %, 1.2 %, 1.6 %, 2 %, and 2.4 %) were developed and its performance on SS 304 steel was investigated. Results and discussion. The fi nding revealed that with an increase in the mass concentration, the thermophysical properties improve. In addition, it is shown that friction decreases with an increase in the particle concentration to 1.6 wt. %. At a concentration of 1.6 wt. % of CuO/Al2O3 hybrid cutting nanofl uid showed the best performance characteristics. This study also provides a comparison with dry turning. The highest tool wear was observed in dry turning, followed by turning using corn oil. A 32 % reduction in cutting force is observed. The surface roughness when using CuO/Al2O3 hybrid cutting nanofl uid is reduced by 27.7 %. However, when using a hybrid nanofl uid (2.4 % of CuO/Al2O3), low tool wear is observed. In this study, the possibility of using vegetable-based hybrid nanofl uids for metal turning with a minimum amount of lubricant is considered. For citation: Manikanta J.E., Ambhore N., Shamkuwar S., Gurajala N.K., Dakarapu S.R. Investigation of vegetable-based hybrid nanofl uids on machining performance in MQL turning. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 4, pp. 6–18. DOI: 10.17212/1994-6309-2024-26.4-6-18. (In Russian). ______ * Corresponding author Ambhore Nitin, Ph.D. (Engineering), Assistant Professor Vishwakarma Institute of Technology, Pune - 411037, Maharashtra, India Tel.: +91-2026950441, e-mail: nitin.ambhore@viit.ac.in Introduction During machining, a large amount of heat is generated in the cutting zone and friction occurs, which reduces performance [1]. Therefore, eff ective cutting fl uids and methods of introducing lubricant between the rubbing surfaces are required. Cutting fl uids help to maintain a low temperature in the contact zone of the tool and the workpiece [2, 3]. To some extent, traditional cooling methods and cutting fl uids serve this objective, but intensive use of conventional cutting fl uids leads to environmental pollution and is also toxic
OBRABOTKAMETALLOV TECHNOLOGY Vol. 26 No. 4 2024 to human beings [4]. Dry machining is an alternative to conventional cooling to ensure clean metal cutting operations without any environmental and worker health problems [5–7]. Some researchers have conducted metal cutting under dry conditions and found positive results in terms of machining performance. However, in most cases, dry machining with large cutting depths and high speeds cannot be the preferred method, since machining under such conditions reduces tool life [8–9]. In view of the above, a potential method of minimum quantity coolant (MQL) turning aims to reduce the consumption of cutting fl uid. In this method, a small amount of cutting fl uid is supplied to the machining zone. Generally, base fl uids have good lubricating properties, but its low cooling capacity limits its use in high-speed cutting operations using MQL. Currently, nanometer-sized are combined with traditional fl uids to improve performance [10–13]. Song et al. [14] added multi-walled carbon nanotubes to conventional cutting fl uid and found a 200 % improvement in thermal conductivity. Usluer et al. [15] investigated the eff ect of hybrid nanofl uid in MQL turning. The results showed that the feed rate had the most signifi cant eff ect on the cutting force and axial thrust force (86.8 and 65 %, respectively), while the cutting conditions had the greatest eff ect on the cutting temperature (93.2%). Senkan et al. [16] added silicon dioxide (SiO2) nanoparticles to sunfl ower oil and used the resulting hybrid nanocoolant in turning AISI 304 steel. The results showed that the surface roughness was greatly aff ected by the feed rate. The cooling method had a signifi cant eff ect on the cutting zone temperature and tool wear. Ngoc et al. [17] investigated the performance of Al2O3/MoS2 hybrid nanofl uid and Al2O3 and MoS2 mono-nanofl uids in MQL turning of 90CrSi steel parts. The results showed that lower cutting temperature was observed and the surface roughness and cutting force were less. Junankar et al. [18] investigated the eff ect of vegetable oil-based nanofl uid on MQL turning of bearing steel. The hybrid nanofl uid reduced the surface roughness and cutting temperature by 65 and 11 %, respectively. Ibrahim et al. [19] investigated the eff ect of rice bran oil on the machining performance of AISI D3 steel turning. The experimental results showed that the cutting force was reduced by 18.48 %, the tool wear was reduced by 51.96 %, and the machined surface roughness was reduced by 12.84 %. Ngol [20] evaluated the machining performance of 90CrSi steel under MQL by adding Al2O3 and MoS2 nanoparticles into the base liquid soybean oil and emulsion. The results showed that MQL turning with the nanofl uid made of MoS2, emulsion and soybean could signifi cantly reduce the total cutting force. Pasam and Neelam [21] studied the machining performance of titanium alloys using hybrid cutting fl uids based on vegetable oil. The developed cutting fl uids reduced the cutting force and cutting temperature, increased the microhardness of the machined surface and favorable residual stresses. Usca [22] studied the machining performance of Dillimax 690T material using a cellulose nanocrystal-based nanofl uid under MQL. According to the test results, signifi cant cutting temperature, surface roughness, tool wear and energy consumption were observed. Singh et al. [23] studied the eff ect of nanoparticle concentration on turning of Hastelloy C-276 under MQL. The study found that higher nanoparticle concentration improved thermal conductivity by 12.28 %, surface roughness by 27.88 %, temperature by 16.8 % and tool wear by 22.5 %. Das et al. [24] evaluated the turning performance of AISI 4340 steel using four diff erent nanofl uid compositions under MQL. The authors found that CuO nanofl uid had superior eff ect on cutting force and tool wear. Bai et al. [25] evaluated the milling performance of Al2O3 and cottonseed oil based nanofl uids under MQL. The results showed that the surface roughness was 1.63 μm at 0.5 wt. % Al2O3 in cottonseed oil. Researchers have tried to investigate the machining performance using various vegetable oils such as sunfl ower, soybean and cottonseed ones. However, the machining performance using corn oil has not been studied. The aim of this study is to use copper oxide-aluminum oxide hybrid nanoparticles (CuO/Al2O3) in combination with corn oil. The work also investigated the thermal, antifriction and antiwear properties of the hybrid nanofl uids in diff erent concentrations and its eff ect on the machining of SS 304 steel. Methods First, a cutting fl uid was prepared using 30 nm diameter CuO and Al2O3 nanoparticles supplied by Platonic Nanotech in Jharkhand, India. The mixing ratio of corn oil with CuO and Al2O3 nanoparticles
OBRABOTKAMETALLOV Vol. 26 No. 4 2024 TECHNOLOGY was 1:1.5. To improve stability, a surfactant, sodium dodecyl benzene sulfonate (10 % load of nanoparticles), was added to the base oil. A total of six hybrid cutting fl uids of 100 ml (0.4 %, 0.8 %, 1.2 %, 1.6 %, 2 % and 2.4 %) were created by varying the weight concentration of the hybrid nanoparticles in the fl uid. A homogeneous mixture was obtained by magnetic stirring for one hour and ultrasonic stirring for two hours. The stability of the hybrid nanofl uid was evaluated using conventional sedimentation methods. All the hybrid nano cutting fl uid (HCF) samples were collected in 10 ml measuring jars and kept frozen for 72 hours before being used. The specifi c heat capacity and thermal conductivity were measured using diff erential scanning calorimetry and a Pro thermal analyzer, respectively. A rheometer (manufacturer Anton Paar) was used to measure the viscosity of the developed nanofl uid. Three independent tests were conducted, the results of which were averaged to determine the viscosity. To study the tribological properties of HCF, pin-and-disk tests were carried out. Diff erent weight concentrations of CuO/Al2O3 in corn oil were investigated tested using a pin-on-disc tester. Corn oil was preferred as the base for the preparation of nanofl uids due to its availability, costeff ectiveness and desirable thermal properties. Corn oil is a common vegetable oil with good thermal stability and moderate viscosity, making it suitable for dispersing nanoparticles and improving the heat transfer properties of nanofl uids. According to ASTM G 99, a maximum load of 200 N and a rotation speed of 2,000 rpm were allowed during the friction test. To determine the friction coeffi cient using the pin-ondisc setup, a pin is applied to a rotating disk under controlled conditions to measure the frictional resistance between the two surfaces. The approach used in this study is shown in Fig. 1. The turning experiments were carried out using the center lathe machine (Turn-master-35) shown in Fig. 2 with the feed rate of the prepared cutting fl uid (CuO/Al2O3) of 10 ml/s. The SS 304 alloy workpiece with a length of 200 mm and a diameter of 50 mm was machined using the SNMG120408 NSU (coated carbide) tool. The cutting parameters were selected according to the manufacturer’s recommendations for the tool and workpiece. The detailed information of the experimental setup is given in Table 1. The cutting speed, feed, and depth of cut were fi xed at 1,000 rpm, 90 mm/rev, 0.15 mm, respectively. During the turning process, the cutting force, tool tip temperature, and machined workpiece’s fi nish were measured using a piezoelectric dynamometer, digital pyrometer, and surface roughness tester, respectively. The tool fl ank wear was measured using an optical microscope. Table 2 shows the process parameters and MQL environment. Fig. 1. Experimental methodology
OBRABOTKAMETALLOV TECHNOLOGY Vol. 26 No. 4 2024 Fig. 2. Experimental setup for turning with MQL Ta b l e 1 Details of experimental setup Parameter Description Machine tool Center lathe machine, Turn-master-35, (Make: Kirloskar) Workpiece material SS 304 alloy Workpiece size Diameter 50 mm, length 200 mm Tool holder PSBNR 2525M-12 Cutting tool SNMG 120408 NSU (Coated Carbide) Ta b l e 2 Process Parameters and MQL Environment Speed (rev/min) 1000 Feed (mm/min) 90 Depth of cut (mm) 0.3 Base oil Corn oil Surfactants SDBS Concentration of surfactants 10 (wt. % of np) Nanoparticles Copper oxide/alumina (CuO/Al2O3) Hybrid ratio 1:1.5 Weight concentration 0.4,0.8,1.2,1.6, 2, 2.4 Lubrication MQL fl ow rate of 10 mL/sec Temperature measurement Digital pyrometer Cutting force measurement Piezoelectric type, Kistler 9257B Tool wear measurement Optical Microscope
OBRABOTKAMETALLOV Vol. 26 No. 4 2024 TECHNOLOGY Results and Discussion In this study, the stability of corn oil-based CuO/Al2O3 hybrid nanofl uids was investigated by visual observation. After 96 hours of sample preparation, it was observed that the CuO/Al2O3 hybrid nanofl uids in the ratio of 1:1.5 were most stable at the weight fraction of 0.4 and 1.6. Increasing the concentration led to increased aggregation and hence decreased stability. The stability test results of corn oil-based CuO/Al2O3 hybrid nanofl uids for diff erent weight concentrations are shown in Fig. 3. Fig. 3. Results of a 96-hour sedimentation test Fig. 4, a shows the viscosity results using diff erent concentrations of CuO/Al2O3 hybrid nanofl uids. The viscosity can be increased by using hybrid nanoparticles in addition to the base oil with a particle concentration of 0.4–2.4 wt. %. The CuO/Al2O3 hybrid nanofl uid becomes more viscous as a result of increasing the particle concentration in the liquid. The viscosity of the solution decreased with increasing temperature. As a result of the decrease in intermolecular cohesion between particles at higher temperatures, the viscosity becomes less signifi cant. Fig. 4, b shows the eff ect of temperature on thermal conductivity. This can be achieved by increasing the nanoparticle content (weight percent) in CuO/Al2O3 hybrid nanofl uids and temperature. Fig. 4, b also shows that the thermal conductivity of the material was improved by adding nanoparticles due to Brownian motion and the huge surface area of nanofl uids. Fig. 4, c shows that the experimental values of specifi c heat capacity of CuO/Al2O3 HCF increase with the increase of particle concentration (in percent by weight). The specifi c heat capacity increases with the increase of nanoparticle concentration and temperature. At the nanoparticle concentration of 2.4 wt. %, the specifi c heat capacity of CuO/Al2O3 hybrid cutting fl uid is 11.86 % higher than that of the base oil. This is probably due to the high stability of HCF. The thermal conductivity and specifi c heat capacity of HCFs were improved, which enables it to dissipate heat more effi ciently. The tribological properties of hybrid nanofl uids can be evaluated using the pin-on-disk friction test. By mixing copper oxide and aluminum oxide hybrid nanoparticles with corn oil, a thin tribofi lm is formed between the pin and the disk. The fi lm thickness and the obtained result become larger with the increase of the amount of nanoparticles to a certain ratio. Fig. 4, d shows the decreasing pattern of the friction coeffi cient up to 1.6 wt. %, and then the increasing pattern of the friction coeffi cient after 1.6 wt. % is observed. After increasing to 1.6 wt. %, the friction coeffi cient is proportional to the content of nanoparticles, which indicates that the lubricating properties of the developed cutting fl uid are eventually reduced. The reason is the agglomeration of nanoparticles observed as a result of sedimentation. The minimum friction coeffi cient of 0.124 is observed at a content of 1.6 wt. % of CuO and Al2O3 in hybrid nanofl uids.
OBRABOTKAMETALLOV TECHNOLOGY Vol. 26 No. 4 2024 a b c d Fig. 4. Viscosity (a); thermal conductivity (b); specifi c heat (c); coeffi cient of friction (d) Under continuous cutting conditions, an electric dynamometer with a piezo sensor mounted on the lathe measured the cutting forces in real time. The measured cutting forces are shown in Fig. 5, a for various lubrication conditions. Consistently low particle concentrations reduce all forces, while higher concentrations increase it only slightly. As the concentration of nanoparticles increases, a dense or slurry layer is formed, which increases the cutting force. At a CuO/Al2O3 content of 1.6 wt. %, the cutting force decreases by 32 %. This is due to the formation of an adhesive coating between the sliding surfaces due to the layered nanoscale structure of Al2O3, which also makes the metal surfaces more easily absorbable. This can be seen from the friction coeffi cient in Fig. 4, d. CuO/Al2O3 HCF also has a higher viscosity than the base fl uid. The thick fi lm that forms during cutting eventually reduces the cutting pressure on the contacting surfaces. The cutting temperature can be aff ected by the heat generated at the chip-tool interface. A digital pyrometer was used to determine the temperature of CuO/ Al2O3 HCF. Fig. 5, b shows diff erent lubrication conditions aff ecting the cutting temperature. The cutting temperature was signifi cantly reduced by using the CuO/Al2O3 hybrid nanofl uid. The reduction in cutting temperature can be achieved when the copper and aluminum oxide concentration is as low as 2.4 %. Compared with other concentrations, the sample containing 1.6 wt. % CuO/Al2O3 has the lowest cutting temperature (67 °C). The hybrid nano cutting fl uid containing 1.6 wt. % CuO/Al2O3 reduces the cutting temperature by 43.4 % compared with the traditional cutting fl uid. By using this HCF, the thermal conductivity and heat transfer coeffi cient of the CuO/Al2O3 nano cutting fl uid can be improved to reduce the temperature in the cutting zone. The eff ectiveness of cutting fl uids is determined by its ability to reduce the surface roughness of the workpiece. Fig. 5, c shows the measured surface roughness. With an increase in the concentration of
OBRABOTKAMETALLOV Vol. 26 No. 4 2024 TECHNOLOGY a b c d Fig. 5. The eff ect of the composition of the coating on: cutting force (a); cutting temperature (b); surface roughness (c); tool fl ank wear (d) nanoparticles, the roughness value (Ra) decreases from 5.4 to 1.6 %, and then increases as the concentration increases. This may be due to the aggregation of nanoparticles. The surface roughness (Ra) when using HCF CuO/Al2O3 is reduced by 27.7 and 23.8 %, respectively, compared with dry cutting and cutting using base oil as a cutting fl uid. Due to the minimal shear resistance between the tool and the workpiece, caused by the affi nity of the tool to metal surfaces, the friction between the tool and the workpiece is minimized. Measuring the fl ank wear helps to predict the remaining service life of the cutting tool. By measuring the fl ank wear, operators can monitor the tool condition in real time. It is possible to increase the service life of the tool by reducing its wear. Fig. 5, b shows the study of tool wear under various lubrication conditions. Fig. 6, a, b shows the tool wear with 2 % hybrid nanofl uid and 0.8 % hybrid nanofl uid, respectively. By using corn oil with a higher CuO/Al2O3 content than the base oil, the tool fl ank wear is signifi cantly reduced. Reduced friction means less heating and less tool wear, which are both positive things. As a result, a very thin layer is formed between the workpiece and the tool. Alternatively, the reduction in tool fl ank wear may be due to the synergistic combination of the ball bearing properties of CuO and Al2O3 nanoparticles. Conclusions In this study, corn oil-based nanofl uids with diff erent concentrations of CuO + Al2O3 are prepared and tested for turning performance. The cutting force, surface roughness and tool are investigated. The results show that the use of hybrid nanofl uids under MQL can improve the machining performance of SS 304. In all
OBRABOTKAMETALLOV TECHNOLOGY Vol. 26 No. 4 2024 a b Fig. 6. Tool wear when using 2 % hybrid nanofl uid (a); tool wear when using 0.8 % hybrid nanofl uid (b) tests, HCF with 0.4 and 1.6 wt. % of CuO/Al2O3 showed little sedimentation. The properties of CuO/Al2O3 cutting fl uid such as specifi c heat, viscosity and thermal conductivity are improved by increasing the particle concentration and temperature. The developed cutting fl uid reduces the friction coeffi cient compared with dry turning and turning using 1.6 wt. % base oil as cutting fl uid. The highest tool wear is observed in dry turning, followed by turning using corn oil. The developed hybrid nano cutting fl uid reduces cutting force, temperature, and improves surface quality at a concentration of 1.6 wt.% CuO/Al2O3. When using a hybrid nanofl uid with a concentration of 2.4 wt. % CuO/Al2O3, low tool wear is observed. References 1. Singh G., Aggarwal V., Singh S., Singh B., Sharma S., Singh J., Li C., Królczyk G., Kumar A., Eldin S.M. Performance investigations for sustainability assessment of Hastelloy C-276 under diff erent machining environments. Heliyon, 2023, vol. 9 (3). DOI: 10.1016/j.heliyon.2023.e13933. 2. Bedi S.S., Behera G.C., Datta S. Eff ects of cutting speed on MQLmachining performance of AISI 304 stainless steel using uncoated carbide insert: application potential of coconut oil and rice bran oil as cutting fl uids. Arabian Journal for Science and Engineering, 2020, vol. 45, pp. 8877–8893. DOI: 10.1007/s13369-020-04554-y. 3. Eswara J.E., Raju B.N., Prasad C., Sankar B.S.S.P. Machining performance on SS304 using nontoxic, biodegradable vegetable-based cutting fl uids. Chemical Data Collections, 2022, vol. 42. DOI: 10.1016/j. cdc.2022.100961. 4. Ambhore N., Kamble D.,Agrawal D. Experimental investigation of induced tool vibration in turning of hardened AISI52100 steel. Journal of Vibration Engineering & Technologies, 2022, vol. 10, pp. 1679–1689. DOI: 10.1007/ s42417-022-00473-4. 5. Ali M.A.M., Azmi A.I., Murad M.N., Zain M.Z.M., Khalil A.N.M., Shuaib N.A. Roles of new bio-based nanolubricants towards eco-friendly and improved machinability of Inconel 718 alloys. Tribology International, 2020, vol. 144. DOI: 10.1016/j.triboint.2019.106106. 6. Singh G., Aggarwal V., Singh S. Critical review on ecological, economical and technological aspects of minimum quantity lubrication towards sustainable machining. Journal of Cleaner Production, 2020, vol. 271. DOI: 10.1016/j.jclepro.2020.122185. 7. Kumar M.S., Krishna V.M. An investigation on turning AISI 1018 steel with hybrid biodegradeable nanofl uid/ MQL incorporated with combinations of CuO-Al2O3 nanoparticles. Materails Today: Proceedings, 2020, vol. 24, pp. 1577–1584. DOI: 10.1016/j.matpr.2020.04.478. 8. Zhang S., Li J.F., Wang Y.W. Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions. Journal of Cleaner Production, 2012, vol. 32, pp. 81–87. DOI: 10.1016/j.jclepro.2012.03.014. 9. Rajaguru J., Arunachalam N. A comprehensive investigation on the eff ect of fl ood and MQL coolant on the machinability and stress corrosion cracking of super duplex stainless steel. Journal of Materials Processing Technology, 2020, vol. 276. DOI: 10.1016/j.jmatprotec.2019.116417.
OBRABOTKAMETALLOV Vol. 26 No. 4 2024 TECHNOLOGY 10. Tefera A.G., Sinha D.K., Gupta G. Experimental investigation and optimization of cutting parameters during dry turning process of copper alloy. Journal of Engineering and Applied Science, 2023, vol. 70 (1), p. 145. DOI: 10.1186/s44147-023-00314-5. 11. Nune M.M.R., Chaganti P.K. Development, characterization, and evaluation of novel eco-friendly metal working fl uid. Measurement, 2019, vol. 137, pp. 401–416. DOI: 10.1016/j.measurement.2019.01.066. 12. Manikanta J.E., Raju B.N., Ambhore N., Santosh S. Optimizing sustainable machining processes: a comparative study of multi-objective optimization techniques for minimum quantity lubrication with natural material derivatives in turning SS304. International Journal on Interactive Design and Manufacturing, 2024, vol. 18 (2), pp. 789–800. DOI: 10.1007/s12008-023-01706-w. 13. Asadi A., Asadi M., Rezaniakolaei A., Rosendahl L.A., Afrand M., Wongwises S. Heat transfer effi ciency of Al2O3-MWCNT/thermal oil hybrid nanofl uid as a cooling fl uid in thermal and energy management applications: an experimental and theoretical investigation. International Journal of Heat and Mass Transfer, 2017, vol. 117, pp. 474–486. DOI: 10.1016/j.ijheatmasstransfer.2017.10.036. 14. Song Y., Cao H., Qu D., Yi H., Kang X., Huang X., Zhou J., Yan C. Surface integrity optimization of high speed dry milling UD-CF/PEEK based on specifi c cutting energy distribution mechanisms eff ected by impact and size eff ect. Journal of Manufacturing Processes, 2022, vol. 79, pp. 731–744. DOI: 10.1016/j.jmapro.2022.05.024. 15. Usluer E., Emiroğlu U., Yapan Y.F., Kshitij G., Khanna N., Sarıkaya M., Uysal A. Investigation on the eff ect of hybrid nanofl uid in MQL condition in orthogonal turning and a sustainability assessment. Sustainable Materials and Technologies, 2023, vol. 36 (16), p. e00618. DOI: 10.1016/j.susmat.2023.e00618. 16. Şencan A.Ç., Şirin Ş., Saraç E.N.S., Erdoğan B., Koçak M.R. Evaluation of machining characteristics of SiO2 doped vegetable based nanofl uids with Taguchi approach in turning of AISI 304 steel. Tribology International, 2024, vol. 191. DOI: 10.1016/j.triboint.2023.109122. 17. Ngoc T.B., Duc T.M., Tuan N.M., Hoang V.L., Long T.T. Machinability assessment of hybrid nano cutting oil for minimum quantity lubrication (MQL) in hard turning of 90CrSi steel. Lubricants, 2023, vol. 11 (2), p. 54. DOI: 10.3390/lubricants11020054. 18. Junankar A.A., Yashpal Y., Purohit J.K. Experimental investigation to study the eff ect of synthesized and characterized monotype and hybrid nanofl uids in minimum quantity lubrication assisted turning of bearing steel. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 2022, vol. 236 (9), pp. 1794–1813. 19. Ibrahim A.M.M., Omer M.A., Das S.R., Li W., Alsoufi M.S., Elsheikh A. Evaluating the eff ect of minimum quantity lubrication during hard turning of AISI D3 steel using vegetable oil enriched with nano-additives. Alexandria Engineering Journal, 2022, vol. 61 (12), pp. 10925–10938. 20. Ngol M.T. Infl uence of technology parameters on the total cutting force in the hard turning process with NF MQL and NF MQCLmethod using nanofl uids. Tribology in Industry, 2023, vol. 44 (2), pp. 272–284. DOI: 10.24874/ ti.1453.02.23.05. 21. PasamV.K., Neelam P. Eff ect of vegetable oil-based hybrid nano-cutting fl uids on surface integrity of titanium alloy in machining process. Smart and Sustainable Manufacturing Systems, 2020, vol. 4 (1), pp. 1–18. 22. Usca Ü.A. The eff ect of cellulose nanocrystal-based nanofl uid on milling performance: an investigation of dillimax 690T. Polymers, 2023, vol. 15 (23), p. 4521. DOI: 10.3390/polym15234521. 23. Singh G., Sharma S., SeikhA.H., Li C., Zhang Y., Rajkumar S., Kumar A., Singh R., Eldin S.M. Anovel study on the infl uence of graphene-based nanofl uid concentrations on the response characteristics and surface-integrity of Hastelloy C-276 during minimum quantity lubrication. Heliyon, 2023, vol. 9 (9), p. e19175. DOI: 10.1016/j. heliyon.2023.e19175. 24. DasA., Patel S.K., Das S.R. Performance comparison of vegetable oil based nanofl uids towards machinability improvement in hard turning of HSLA steel using minimum quantity lubrication. Mechanics & Industry, 2019, vol. 20 (5), p. 506. DOI: 10.1051/meca/2019036. 25. Bai X., Jiang J., Li C., Dong L., Ali H.M., Sharma S. Tribological performance of diff erent concentrations of Al2O3 nanofl uids on minimum quantity lubrication milling. Chinese Journal of Mechanical Engineering, 2023, vol. 36 (1), p. 11. Confl icts of Interest The authors declare no confl ict of interest. © 2024 The Authors. Published by Novosibirsk State Technical University. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0).
RkJQdWJsaXNoZXIy MTk0ODM1