Vol. 27 No. 1 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. 1 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. 1 2025 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Umerov E.D., Skakun V.V., Dzhemalyadinov R.M., Egorov Y.A. Investigation of the eff ect of oil-based MWFs with enhanced tribological properties on cutting forces and roughness of the processed surfaces.............................................. 6 Manikanta J.E., Ambhore N., Thellaputta G.R. Investigation of vegetable oil-based cutting fl uids enhanced with nanoparticle additions in turning operations........................................................................................................................ 20 Shlykov E.S., Ablyaz T.R., Blokhin V.B., Muratov K.R. Improvement the manufacturing quality of new generation heat-resistant nickel alloy products using wire electrical discharge machining................................................................... 34 Ablyaz T.R., Osinnikov I.V., Shlykov E.S., Kamenskikh A.A., Gorohov A.Yu., Kropanev N.A., Muratov K.R. Prediction of changes in the surface layer during copy-piercing electrical discharge machining....................................... 48 Martyushev N.V., Kozlov V.N., Boltrushevich A.E., Kuznetsova Yu.S., Bovkun A.S. Milling of Inconel 625 blanks fabricated by wire arc additive manufacturing (WAAM)..................................................................................................... 61 Fatyukhin D.S., Nigmetzyanov R.I., Prikhodko V.M., Sundukov S.K., Sukhov A.V. Infl uence of the oscillating systems inclination angle on the surface properties of steel 45 during ultrasonic surface plastic deformation................... 77 EQUIPMENT. INSTRUMENTS Borisov M.A., Lobanov D.V., Skeeba V.Y., Nadezhdina O.A. Development of a device for studying and simulating the electrochemical grinding process................................................................................................................................... 93 Lapshin V.P., Gubanova A.A., Dudinov I.O. Predicting machined surface quality under conditions of increasing tool wear............................................................................................................................................................................... 106 Podgornyj Y.I., Skeeba V.Y., Martynova T.G., Sadykin A.V., Martyushev N.V., Lobanov D.V., Pelemeshko A.K., Popkov A.S. Designing the homogenization mechanism.................................................................................................... 129 MATERIAL SCIENCE Usanova O.Yu., Ryazantseva A.V., Vakhrusheva M.Yu., Modina M.A., Kuznetsova Yu.S. Improving the performance characteristics of grey cast iron parts via ion implantation.......................................................................... 143 Abdelaziz K., Saber D. Fabrication and characterization of Al-7Si alloy matrix nanocomposite by stir casting technique using multi-wall thickness steel mold................................................................................................................ 155 Dama Y.B., Jogi B.F., Pawade R., Pal S., Gaikwad Y.M. DLP 3D printing and characterization of PEEK-acrylate composite biomaterials for hip-joint implants....................................................................................................................... 172 Prudnikov A.N., Galachieva S.V., Absadykov B.N., Sharipzyanova G.Kh., Tsyganko E.N., Ivancivsky V.V. Eff ect of deformation thermocyclic treatment and normalizing on the mechanical properties of sheet Steel 10.......................... 192 Bhanavase V., Jogi B.F., Dama Y.B. Wear behavior study of glass fi ber and organic clay reinforced poly-phenylenesulfi de (PPS) composites material........................................................................................................................................ 203 EDITORIALMATERIALS 218 FOUNDERS MATERIALS 227 CONTENTS
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology Investigation of the effect of oil-based MWFs with enhanced tribological properties on cutting forces and roughness of the processed surfaces Ervin Umerov 1, 2, a,*, Vladimir Skakun 1, 2, b, Ruslan Dzhemalyadinov 1, 2, c, Yuriy Egorov 2, d 1 Crimean Engineering and Pedagogical University named after Fevzi Yakubov, 8 Uchebnyy side st., Simferopol, 295015, Russian Federation 2 V.I. Vernadsky Crimean Federal University, 4 Academician Vernadsky ave., Simferopol, 295007, Russian Federation a https://orcid.org/0000-0003-3477-2036, Ervin777@yandex.ru; b https://orcid.org/0000-0003-0656-7852, vladimir.skakun.92@list.ru; c https://orcid.org/0000-0003-3319-3542, rus.dzhemalyadinov@mail.ru; d https://orcid.org/0000-0003-4990-9998, yuriyegorov@cfuv.ru 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. 1 pp. 6–19 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2025-27.1-6-19 ART I CLE I NFO Article history: Received: 16 October 2024 Revised: 26 October 2024 Accepted: 21 November 2024 Available online: 15 March 2025 Keywords: Lubricating and cooling technological means Coefficient of friction Cutting forces Roughness Funding The research was carried out with the financial support of the Russian Science Foundation (project No. 24-1220013). ABSTRACT Introduction. One way to enhance the efficiency of the cutting process is to develop new effective compositions of metalworking fluids (MWFs), which will reduce cutting force and temperature, while increasing the durability of the cutting tool and the quality of the processed surface. One approach to address this challenge is the chemical activation of MWF using additives based on nanoclay minerals, which are characterized by low cost and abundant reserves in-Earth. In this regard, the theoretical rationale for the selection of this additive and its impact on the tribological properties of the MWF is given. The purpose of the work is to determine the effect of oil-based additives with nanoclay minerals on reducing the cutting force, as well as improving the quality of the processed surface when drilling corrosion-resistant steel. Research methods. Experimental investigations were conducted during a drilling operation, in which the components of the cutting force were recorded using a three-component dynamometer M-30-3-6k. The aim of the experiment was to determine the effect of oil-based MWF containing additives from nanoclay minerals on the component of the cutting force, as well as the roughness of the processed surface. A formula for calculating the friction coefficient in the drilling process was derived using mathematical modeling. Results and Discussion. The experimental investigations yielded results demonstrating the effectiveness of using oil-based MWF with additives made from nanoclay minerals. Experimental data was obtained for the friction coefficient, cutting force component, as well as the roughness of the processed surface during drilling. These results were obtained using the experimental MWF, supplied to the cutting zone. The results of the study showed the effectiveness of using the modified MWF compared to traditional compositions. Conclusions. The modified MWF, which includes sunflower oil and nanoclay minerals as additives, significantly reduces the friction coefficient, cutting force, as well as the roughness of the processed surface, which opens up further prospects for its use in the metalworking industry. For citation: Umerov E.D., Skakun V.V., Dzhemalyadinov R.M., Egorov Y.A. Investigation of the effect of oil-based MWFs with enhanced tribological properties on cutting forces and roughness of the processed surfaces. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 1, pp. 6–19. DOI: 10.17212/1994-6309-2025-27.1-6-19. (In Russian). ______ * Corresponding author Umerov Ervin D., Ph.D. (Engineering), Associate Professor Crimean Engineering and Pedagogical University named after Fevzi Yakubov 8 Uchebnyy side st., 295015, Simferopol, Russian Federation Tel.: +7 978 832-72-92, e-mail: Ervin777@yandex.ru Introduction The development of domestic machine building is a priority task for the modern state. Therefore, it is important both to improve existing technologies and to explore new solutions that enhance the quality and productivity of machining processes while maintaining a low cost for the finished product. One promising solution is the development of novel metalworking fluid (MWFs) compositions that combine high lubricating and cooling performance. Studying their influence on the machining process is essential to identify new avenues for their effective application. One approach is the use of environmentally safe MWFs based on vegetable oils. Critically, the production of such MWFs should be economically viable and avoid excessive financial expenditure.
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 The primary function of oil-based MWFs is lubrication, which ensures the required quality of the processed surface. However, their cooling capacity is limited. In most production facilities, water-soluble MWFs (emulsions) are used; these effectively reduce the temperature in the cutting zone through convective heat exchange due to high-volume supplying, but their lubricating properties are less effective. Numerous scientific studies have analyzed methods for activating and improving MWFs used in the blade machining of workpieces. The authors of these studies have made significant contributions to understanding the mechanism of action of MWFs in the cutting process [1–4]. In this case, MWFs activation involves adding functional additives of various natures and chemical structures, including active organic components containing phosphorus, chlorine, and sulfur. These elements form protective films on contact surfaces, preventing molecular bonding between the tool and the workpiece. Graphite, soft metal powders (molybdenum disulfite) and highly dispersed powders (e.g., serpentine), classified as nanostructured additives, are also viable. They reduce friction in the cutting zone due to antifriction properties by increasing the number of supporting contact areas between the tool and the workpiece. Additionally, some chemical compounds and additives used in MWFs exhibit carcinogenic properties, posing a negative impact on human health and the environment. The analysis of the scientific and technical literature has shown that existing methods for activating oil-based MWFs can be significantly improved. Furthermore, the development of new, cost-effective oilbased MWFs possessing an endothermic (cooling) effect and improved tribological (lubricating) properties remains an important goal. Achieving this goal is possible by adding nanoclay mineral additives to the composition of oil-based MWFs. Based on their physical and mechanical properties, these minerals are similar to additives such as molybdenum disulfite, graphite, and serpentine. A key difference of these nanoclay mineral additives is their ability to undergo hydrocracking of their structural packet layers during hydrogenation. This results in hydro-lubrication between the layers, which contributes to increased tribological efficiency of the oil-based MWF [5]. Thus, the application of modified oil-based MWFs, using nanoclay mineral additives as a friction modifier, can positively affect the cutting process of hard-to-machine materials and stainless steels, with their inherent low thermal conductivity [6, 7]. Optimal cutting modes [8], the quality of the MWFs used, and the method of its supply [9, 10] influence the plastic deformation process, leading to a decrease in temperature and cutting force, as well as improving the quality of the machined surface and tool durability [11–15]. Consequently, there is a need for theoretical studies, laboratory tests, and practical experiments aimed at developing a modified MWFs that uses nanoclay mineral additives (NMAs) as a friction modifier, combining both high lubricity and a cooling effect, which is necessary for processing hard-to-machine materials and stainless steels. The aim of this work is to determine the effect of oil-based MWFs with nanoclay mineral additives on reducing cutting force and improving the quality of the machined surface during the drilling of stainless steel. Tasks to be solved to achieve this aim: 1) to justify the selection of additives to oil-based MWFs to improve their tribological efficiency; 2) to theoretically and experimentally confirm the effectiveness of using nanoclay mineral additives as a friction modifier in oil-based MWFs and their influence on increasing tribological properties; 3) based on current principles of cutting theory, to analyze the effect of nanoclay mineral additives, present in the oil-based MWFs as a friction modifier, on the components of cutting force and the roughness of the machined surface. Research methodology During blade machining of hard-to-machine materials, as well as stainless steels, the various MWFs’ compositions require the technological medium supplied to the cutting zone to provide both lubrication
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology and cooling. However, increasing the lubricating effect often leads to a deterioration of the cooling effect of such MWFs. This circumstance necessitates the search for alternative solutions that result in MWFs possessing both high lubricating and cooling properties. Based on the above considerations, it became necessary to conduct experimental studies aimed at developing modified oil-based MWFs using NMAs as the primary modifying element. The objective is to reduce energy consumption in the cutting process, improve the quality of the machined part, and extend tool life. The use of NMAs offers several advantages. For instance, they are naturally occurring minerals found in abundant quantities within the Earth’s interior and are relatively inexpensive. One type of nanoclay mineral is bentonite, which is primarily composed of montmorillonite (a nanodispersed silicate with a sheet-like structure). From a physicochemical perspective, NMAs exhibit positive characteristics: they can undergo hydrocracking of their structural packet layers during hydrogenation, providing hydro-lubrication between the layers. This contributes to an increase in the tribological efficiency of the MWFs. This phenomenon distinguishes the tribological properties of montmorillonite from those of the friction modifiers described earlier. During hydrogenation of this additive, compared to the aforementioned frictionmodifiers, the unclinching action of surface-sorbed water causes the friction between mineral packets to transition from dry to liquid or boundary lubrication. When hydrated mineral particles enter the contact zone between the tool and the workpiece, carried by the oil-based MWF, they function as “nanoscale sliding bearings” [16, 17], allowing the tool and workpiece to be in contact, which reduces the probability of adhesive wear of the tool. The temperature generated in the contact zone of the tool and the workpiece acts on the surface watersorbed NMA packets contained in the oil-based MWF, resulting in moisture evaporation and providing an endothermic effect. A unique characteristic of nanoclay minerals is that the released vapor remains in the system during the evaporation process. When the temperature decreases, the vapor condenses, returning to the mineral structure. Improving the tribological characteristics of MWFs is particularly important in the process of cutting hard-to-machine materials, including stainless steels, because access of the MWF to the contact zone is often limited when processing these materials. Consider the case where a standard MWF, without additives to prevent adhesive setting, is used when machining hard-to-machine materials. Due to the high specific loads present in the cutting process acting on the tool contact surfaces, displacement of the MWF and subsequent adhesion of the chip to the tool base occurs. Thus, conditions for adhesive bonding between the front face of the cutting tool and the chip are created (Fig. 1, a). In the second case, using an oil-based MWF with graphite or molybdenum disulfide additive in the cutting process (Fig. 1, b), the additive enters the contact zone and counteracts the adhesion of chips to the cutting tool, thereby improving friction conditions in the cutting zone. This is achieved by preventing adhesive bonding of graphite or molybdenum disulfide layer packets with each other. Given the similarity of crystal lattices between graphite or molybdenum disulfide and nanoclay minerals, shear between layers is possible. In the case of graphite or molybdenum disulfide, this shear occurs “dry”, while in the case of nanoclay minerals, liquid friction conditions are created, accompanied by hydrocracking (Fig. 1, c), which directly influences the tribological properties of the MWFs. To evaluate the thermodynamic transformations of NMA that can occur in oil-based MWFs during machining by cutting, we will analyze their behavior during hydration and dehydration. This additive possesses a crystal lattice consisting of three layers, forming negatively charged packets that create repulsive forces, providing a wedging effect [5]. The aforementioned nanoclay minerals’ inherent thermodynamic properties enable their use as additives to oil-based MWFs. In reference [18], a detailed thermal analysis of montmorillonite is presented, highlighting the temperature range (80–220 °C), in which the endothermic (heat-absorbing) effect is manifested. At the
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 а b с Fig. 1. Examples of possible contact interactions on the rake face of a cutting tool: а – without MWF feeding (“dry” cutting); b – with graphite in the oil-based MWF, acting as an additive; c – with an additive of a hydrogenated nanoclay mineral in the oil-based MWF; – the area of high local deformation; WM – work material; V – linear velocity; TM – tool material initial stage of this range, the adsorption layer of water is removed, followed by the removal of interpacket water from the mineral surface. When the temperature increases to 600 °C, complete destruction (sintering) of the mineral’s crystal lattice occurs, caused by the removal of the structural water layer. It is known that boundary friction occurs during cutting at low contact loads [19], while intensive plastic deformation leads to “grabbing” of chips by the front face of the tool.
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology To evaluate the effectiveness of the NMA described above in the composition of oil-based MWFs, laboratory testswere conducted todetermine the empirical frictioncoefficient under conditions approximating the drilling process. References [20, 21] describe various methods for determining the friction coefficient of lubricants, noting that it is not always possible to assess the actual friction coefficient using a particular machining method, due to the inherent characteristics of each method. Furthermore, the widely used four-ball machine methodology for determining the friction coefficient does not allow for reproducing the friction process occurring, for example, in the contact zone between the cutting tool and the workpiece during drilling. Experimental evaluation of the effectiveness of the developed oil-based MWF with NMA as a friction modifier, as well as evaluation of its tribological properties, was conducted using the “cone spinning on the cone” method for determining the friction coefficient, performed on a radial drilling machine2Co522. The experimental stand functioned as a tribometer, allowing for the determination of the empirical friction coefficient approximating the drilling process. A spiral drill bit made of steel B6Mo5 with a modified cutting edge geometry was used as an indenter (Fig. 2). This provided friction between the indenter (drill bit) and the conical surface of the counterbody (workpiece). During the research process, a three-component dynamometer M-30-3-6k was mounted on the machine table to register both axial force and torque. The workpiece, made of corrosion-resistant steel 0.12 C-18 Cr-10Ni-Ti with a previously drilled hole, was fixed on the dynamometer using a flange and a three-jaw chuck. The indenter was a spiral drill bit with a diameter D = 10 mm and a point angle of 2φ = 118°, made of high-speed steel 6 W-5 Mo-4 Cr-2 V, featuring rounded cutting edges (see Fig. 2). Axial force and torque values were recorded using the three-component dynamometer M-30-36k. The signal from the dynamometer was transmitted to a personal computer through an amplifier and analog-to-digital converter for subsequent generation of dependence diagram. Fig. 6 illustrates the general view of the experimental stand. A protective screen was used to prevent the measuring equipment from being splashed with MWF during the research process. The laboratory testing procedure was as follows: the counterbody 4 was fixed on the dynamometer using a three-jaw chuck and a flange. The indenter 1 was fixed in the machine spindle using a chuck. After starting the machine and subsequent feeding the tested modified MWF through slot 2 into the contact zone, the axial load on the counterbody was gradually increased to the required value P0, followed by measuring the friction torque. The spindle speed was 500 rpm with an axial load on the indenter of P0 = 2,000 N. To compare effectiveness, the following MWF compositions were used: vegetable oil (sunflower oil), industrial oil I-20A, vegetable oil (sunflower oil) with NMA, and industrial oil I-20A with NMA, at a constant MWF supply rate of 0.5 l/min. Fig. 3 presents the results of experimental studies to determine the empirical friction coefficient, using the methodology described above. During friction between a rotating indenter (drill bit) and a stationary counterbody, using the friction torque Mfr is more effective than using the friction force. The force of resistance to the movement of the indenter (drill bit’s) relative to the counterbody surface is a distributed force, directed opposite to the velocity vector of the body under consideration. Fig. 2. Geometry of the cutting edge of a modified drill (indenter): 1 – counterbody (workpiece); 2 – indenter (spiral drill); 3 – circular groove for supplying to the cutting zone; 4 – throughhole for removing MWF
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 According to the calculation scheme (Fig. 4), the friction force Ffr is an equivalent force, which can be determined according to the principle of finding equivalent forces for parallel distributed forces. Let us determine its magnitude and the point of its application, which is located at the center of the contact line l between the drill bit and the workpiece. According to the scheme of the friction unit, a pair of forces {−Ffr; Ffr} with a moment acts on the indenter (drill bit): ⋅ + = 0 ( ) , 2 fr fr F D d M (1) where D is the diameter of the indenter (drill bit); d0 is diameter of the hole in the counterbody or = + 0 2 fr fr M F D d . (2) For the unit under consideration, Equation (2) relates the moment and friction force. The axial force PN acting on the contact surface of the tool is the projection of the axial force PN by the sine of the angle between the forces. Using the equilibrium condition, and taking into account the normal pressure force on the indenter (drill) surface PN, which is in contact with the counterbody, we obtain: ⋅ ϕ = 0 sin 2 N P P , (3) where P0 is the axial force, N. According to the Amont-Coulomb law, the normal force PN is related to the friction force Ffr, which can be defined by the following equation: Fig. 3. Friction torque values in various MWF environments Fig. 4. Design scheme of the analyzed friction pair: 2φ – drill apex angle, deg; Ffr – friction force, H; P0 – axial force, H
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology µ ⋅ ⋅ ϕ = µ ⋅ = 0 sin 2 fr N Ð F P , (4) where µ is the empirical coefficient of friction. After transformation, we obtain: µ = + ⋅ ⋅ ϕ 0 0 4 ( ) fr Ì Ð D d sin . (5) Then, using the maximum values of the friction torque, as well as the applied axial force, the empirical coefficient of friction for the considered case is determined. Results and their discussion The measured friction torque Mfr at a constant axial load P0 = 2,000 N using various metalworking fluids (MWFs) is presented graphically in Fig. 5. Analyzing the obtained data (Fig. 5), the maximum empirical coefficient of friction (μ = 0.48) was observed under “dry” friction conditions, without MWF. The addition of NMA as a modifier to MWFs reduces the empirical coefficient of friction. The most significant reduction occurred with sunflower oil (μ = 0.11) compared to mineral oil-based MWF (μ = 0.19). This suggests that the sunflower oil-based MWF with NMA exhibits improved lubricity, providing boundary lubrication, and possibly even liquid lubrication. Fig. 5. Empirical friction coefficient (μ) values in various MWF environments Therefore, sunflower oil modified with NMA is the most effective MWF, compared to sunflower oil without NMA, mineral oil I-20A without NMA, and mineral oil I-20A modified with NMA. This indicates the high lubricating and bearing capacity of the experimental MWF. Determining the empirical friction coefficient using the described methodology provides a quantitative assessment of the tribological properties of the modified MWFs and allows for a more comprehensive understanding of the influence of modifiers, in this case NMA, on the friction force. Following the investigation of the influence of modified MWFs on the empirical friction coefficient, the cutting force during drilling was determined using similar MWFs. To accomplish this, an experimental
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 stand (Fig. 6) equipped with a three-component dynamometer M-30-3-6k with data output to a personal computer was used. This allowed for objective evaluation of the effect of different MWFs on cutting forces during the drilling operation. Fig. 6. Experimental stand for studying cutting forces during drilling As a result of experimental studies of the machining of stainless steel 0.12 C-18 Cr-10Ni-Ti, the cutting force values were obtained as a function of machining time and cutting speed (Fig. 7, a, b). The analysis of the obtained data shows that drilling without MWF results in a high cutting force. Using mineral and sunflower oil-based MWFs as cutting agents reduces the cutting force by 10–20 %. Adding NMA to these oils results in a further reduction in cutting forces (by 9–10 %) compared to the oils without the additive. The smallest cutting force was achieved when using sunflower oil with NMA. NMA, acting as a modifier, improves the tribological properties of oil-based MWFs, contributing to a reduction in temperature within the cutting zone and increasing the lifespan (durability) of the cutting tool [22]. The data presented in the graph (Fig. 7, b) demonstrate that at cutting speeds up to 20 m/min, the type of MWF significantly affects the cutting force PZ. However, as the cutting speed increases, the effectiveness of the MWF decreases. This is attributed to the increased proportion of friction forces generated on the back surface of the tool. Definition of roughness. The influence of NMA on the machined surface surface roughness, which is a critical quality parameter, is also of interest. The roughness of the machined surface is affected by various factors, including cutting modes, the type of MWF and its supply method to the cutting zone, and cutting temperature , etc. [23, 24]. The use of modified oil-based MWFs in drilling workpieces of stainless steel 0.12 C-18 Cr-10Ni-Ti, with NMA as a modifier, enables a reduction in both the cutting temperature and the roughness of the machined surface. Fig. 8 shows the arithmetic mean surface roughness Ra, measured with a profilometer TR-200. Ra reflects the surface roughness of the machined surface.
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology Fig. 7. Tangential cutting force PZ values as a function of processing time (a) and cutting speed (b) with various MWF compositions applied. Tool feed S = 0.076 mm/rpm. Cutting tool – Spiral drill (HSS). D = 22 mm. MWF consumption – 0.5 l/min a b
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 Fig. 8. Results of the arithmetic mean deviation of the Ra profile of the processed surface Conclusions The application of NMA during their hydrogenation, enables the transition to liquid interpacket friction of the mineral layers, creating a hydrobranching zone and improving the tribological properties of oil-based MWFs. This composition allows for the reduction of temperature in the cutting zone through of convective heat distribution within the volume of the MWF with its subsequent removal from the system into the environment. Conducted laboratory studies have shown that, when supplying the oil-based MWF with NMA, the empirical friction coefficient has the lowest value (μ = 0.11) compared to other compositions. NMA included in the composition of oil-based MWF also had a positive effect on the reduction of cutting force during drilling of steel 0.12 C-18 Cr-10 Ni-Ti (by 10 %), compared to using MWF without additives. Furthermore, it reduced the surface roughness of the machined surface to Ra = 3.96 µm. Based on these findings, we conclude that the use of NMA in combination with environmentally safe oils opens fundamentally new ways of their effective use in the cutting process. The primary effects of NMAs are aimed at enhancing the lubricating, cooling, as well as resource-saving action of MWFs. References 1. Vereshchaka A.S., Lierat F., Dyubner L. Analiz osnovnykh aspektov problemy ekologicheski bezopasnogo rezaniya [Analysis of the main aspects of the problem of environmentally safe cutting]. Rezanie i instrument v tekhnologicheskikh sistemakh [Cutting and tool in technological systems]. Kharkiv, 2000, iss. 57, pp. 29–34. 2. Khudobin L.V., Zhdanov V.F. O vozmozhnosti aktivatsii SOZh impul’snymi elektricheskimi polyami [On the possibility of activation of coolant by pulsed electric fields]. Chistovaya obrabotka detalei mashin [Finishing of machine parts]. Saratov, 1980, pp. 49–53. 3. Maddamasetty A., Revuru S., Sitaramaraju A. Performance evaluation of nanographite-based cutting fluid in machining process. Materials and Manufacturing Processes, 2014, vol. 29 (5). DOI: 10.1080/10426914.2014. 893060.
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