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 vegetable oil-based cutting fluids enhanced with nanoparticle additions in turning operations Javvadi Eswara Manikanta 1, a, Nitin Ambhore 2, b, *, Gopala Rao Thellaputta 3, c 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, St. Ann’s College of Engineering & Technology (Autonomous), Chirala, Andhra Pradesh, 523187, 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/0000-0001-5622-4140, drtgopalarao@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. 2025 vol. 27 no. 1 pp. 20–33 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2025-27.1-20-33 ART I CLE I NFO Article history: Received: 11 November 2024 Revised: 25 November 2024 Accepted: 17 December 2024 Available online: 15 March 2025 Keywords: Vegetable oils Nanofluids High-Speed machining Environmental sustainability ABSTRACT Introduction. Currently, the use of vegetable oil-based cutting fluids with nanoparticles is being implemented in turning operations. These fluids provide a sustainable and high-performance solution by improving lubrication, cooling, and surface quality. The use of vegetable oil-based cutting fluids with nanoparticles also promotes an ecofriendly approach in the manufacturing industry. These fluids serve as an alternative to conventional cutting fluids, which are hazardous chemical mixtures that pose a risk to both the environment and the operator. The purpose of the work. The present study focuses on the use of cutting fluids based on environmentally friendly vegetable oils in the turning process. This work investigates the performance of turning AISI 1014 steel with various nanoparticle combinations and ratios. The methods of investigation. In this study, five different vegetable oils — corn oil, coconut oil, sunflower oil, palm oil, and neem oil — were used as base fluid. CuO, Al2O3, graphene, and powdered multi-walled carbon nanotubes were added to the base fluid to create nanofluids. Cutting fluids were developed with varying weight concentrations of 0.20 %, 0.40 %, 0.60 %, 0.80 %, and 1 %, and its performance when machining AISI 1014 steel was investigated. Results and Discussion. The results indicated that, among the vegetable oils, corn oil had the greatest effect on viscosity and thermal conductivity. Graphene nanoparticles showed promising results in reducing cutting force, temperature, and surface roughness. When using corn oil containing 0.8 wt. % graphene nanoparticles, a 104 N reduction in cutting force was observed, this is 29.8 % less than that achieved with pure corn oil. At a high concentration (1 wt. %), the reduction in load decreases due to significant agglomeration of nanoparticles. The optimal nanoparticle concentration in the base fluid (corn oil) is 0.8 wt. %. For citation: Manikanta J.E., Ambhore N., Thellaputta G.R. Investigation of vegetable oil-based cutting fluids enhanced with nanoparticle additions in turning operations. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 1, pp. 20–33. DOI: 10.17212/1994-6309-2025-27.1-20-33. (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 Cutting fluids play a crucial role in metal cutting operations by lubricating the tool-workpiece interface, removing chips from the cutting zone, and cooling the workpiece and cutting tool [1]. However, improper use and disposal of cutting fluids can negatively impact the environment and human health. Turning, a widely used machining process in industries such as marine, energy, construction, and automotive manufacturing, involves removing material from a rotating workpiece using a single-point cutting tool [2]. Turning processes face challenges such as high cutting pressures, friction, tool wear, elevated temperatures at the tool-workpiece interface, and significant energy consumption [3–4]. Improving the sustainability and efficiency of turning requires reducing cutting forces and energy consumption, for which the use of effective cutting fluids is essential [5–6].
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 Conventional mineral oil-based cutting fluids often contain hazardous components such as bactericides, wetting agents, preservatives, and extreme pressure additives, posing risks to the environment and worker health [7]. Furthermore, the recycling and disposal of used cutting fluids contribute to environmental pollution [8]. This has led to increasing interest in alternative lubrication methods for turning operations [9]. Vegetable oil-based lubricants offer an attractive alternative due to their lubricating properties, costeffectiveness, and biodegradability, particularly when used under minimum quantity lubrication (MQL) conditions [10]. MQL can serve as a substitute for flood cooling in terms of tool performance, cost, environmental impact, health, and safety. The use of eco-friendly lubricants and lubrication techniques can significantly reduce the environmental impact of the turning industry while improving machining efficiency and product quality [11]. Several lubricating fluids, including mineral, natural, synthetic, and semi-synthetic oils, are commonly used in turning operations. Researchers have extensively investigated the performance of these fluids. For example, Manikanta et al. [12] found that using maize oil under MQL conditions in turning SS 304 steel improved cutting force, temperature, and tool life compared to dry cutting. Wang et al. [13] investigated the impact of various vegetable oils (soybean, peanut, maize, rapeseed, palm, castor, and sunflower) on the grinding of nickel alloy under MQL. Their findings indicated that coconut oil was readily absorbed into the tools and workpieces and exhibited excellent lubricating effect, while castor oil outperformed other grinding fluids in terms of lubrication and workpiece surface quality. Shaikh and Siddhu [14] reported favorable results when machining D2 steel with a non-edible vegetable oil-based cutting fluid, observing comparable surface finishes for mineral oil, soybean oil, and cottonseed oil (variations less than 10 %). Puttaswamy and Ramachandra [15] explored the feasibility of using Mahua oil and Neem oil as drilling fluids for AISI 304L under MQL at 2 bar pressure, concluding that neem and mahua oil performed better than traditional cutting fluids in all aspects. Li et al. [16] investigated MQL grinding experiments with pure vegetable oil, finding that palm oil was the most suitable base oil for MQL grinding of high-temperature nickel alloy based on energy ratio coefficient and grinding temperature. Similarly, Babu et al. [17] found that olive oil reduced surface roughness and tool wear during milling of AISI 304 steel with MQL, and Radhika et al. [18] observed improved surface quality and reduced cutting force when using sesame oil as a cutting fluid during turning of AISI 1014 steel. Guo et al. [19] investigated six different oils combined with castor oil for MQL grinding, revealing that nanoparticles exhibit excellent tribological properties and thermal conductivity. The addition of nanoparticles can significantly enhance the thermal conductivity and lubricating properties of vegetable oils, improving machining performance [20–21]. Research has focused on the effects of adding nanoparticles to eco-friendly vegetable oils to improve cutting efficiency under MQL. Nam et al. [22] investigated the use of nanofluid MQL in micro-drilling, finding that it led to a significant decrease in drilling torques and thrust forces, as well as an increase in the number of drilled holes, and effectively eliminated remaining chips and burrs, thereby improving the overall quality of drilled holes. Shen et al. [23] dispersed MoS2, diamond, and Al2O3 nanoparticles in vegetable oil to examine forces and tool abrasion in near-dry grinding, finding that MQL using 100 nm diamond nanoparticles at a 1.5 % volume fraction resulted in the greatest force reduction. Vasu et al. [24] investigated the effect of MQL with nano-Al2O3 on the surface quality of Inconel 600, finding that a higher volume fraction of nano-Al2O3 in vegetable oil correlated with improved surface quality. Ni et al. [25] added graphene to castor, corn, and rapeseed oil at varying mass fractions to enhance MQL tapping of ADC12 aluminum alloy, discovering that a 0.5 wt % concentration of graphene yielded the lowest average torque, regardless of the base oil used. High-quality thread surfaces were also achieved with a suspension MQL based on 0.5 wt% castor oil. Zhang et al. [26] created Al2O3 nanofluids by milling Ti6Al-4V under MQL conditions with cryogenic air, finding that the combination of nanofluids and cryogenic air demonstrated superior grinding performance compared to either cryogenic air or Al2O3 nanofluids alone. Manojkumar and Ghosh [27] added multi-walled carbon nanotubes to sunflower oil to grind AISI 52100 steel using small-quantity cooling lubrication (SQCL), showing that the developed liquid improved the workpiece’s surface quality and the wheel’s service life [28].
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology Sustainable practices are crucial in the machining industry, and selecting appropriate cutting fluids is essential for minimizing environmental impact. While previous studies have largely focused on the use of green cutting fluids in various machining operations (turning, milling, drilling, reaming, and grinding), investigations on various vegetable oils with nanoparticle additions and varying ratios are limited. This study aims to address this research gap by employing both pure vegetable oil and vegetable oil-based nanofluids in MQL-assisted machining. The goal of the present study is to determine the optimal vegetable oil for use as a green cutting fluid and evaluate different nanoparticle combinations and ratios to improve machining performance, thus offering a novel perspective on cutting fluid formulations for enhanced machining results. Methods AISI 1014 steel was used as the workpiece material in the turning operation. Corn oil, coconut oil, sunflower oil, palm oil, and neem oil served as the base fluids. Copper oxide nanoparticles (CuO, 99.5 % purity, 30‑50 nm size range), aluminium oxide nanoparticles (Al2O3, 99.5 % purity, 30‑50 nm size range) were supplied by Platonic Nanotech Private Limited Laboratory, India. Multi-walled carbon nanotubes (MWCNTs, 99.9 % purity, 5‑20 nm size range, powdered), and graphene nanoparticles (99.5 % purity, 5‑10 nm size range) were supplied by the same laboratory. Pure corn oil was used as the base fluid, to which nanoparticles were subsequently added to create the nano cutting fluids. The concentrations of mixed powder particles in the base fluid were calculated as follows: 0.20 wt. %, 0.40 wt. %, 0.60 wt. %, 0.80 wt. %, and 1 wt. %. The nanofluids were blended using a magnetic stirrer for three hours followed by ultrasonication for six hours to achieve a uniform and stable suspension. A fresh sample of the stable nanofluid dispersion was used for each test to prevent agglomeration or sedimentation. MQL was implemented on a lathe machine for turning AISI 1014 steel. The schematic diagram of the experimental setup and details of the turning zone are shown in Fig. 1 and Fig. 2, respectively. A coated carbide insert (SNMG120408 NSU) was mechanically clamped onto a rigid tool holder (PSBNR2525M-12). An MQL system consisting of a compressor, flow controller, air dryer, and spray nozzle was used in the machining zone for lubrication. The air supply pressure was 5 bar, and the nanofluid flow rate was 20 ml/ min. The spray nozzle was positioned 4 cm above the tool rake face. Machining parameters (cutting force, cutting temperature, and surface roughness) were examined during turning using a Turn Master 35 Center lathe machine (KIRLOSKAR) in a mist of different concentration nano cutting fluids. Tests were repeated at least three times, and the average results were recorded. Cutting Fig. 1. Experimental methodology
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 force was measured using a Kistler dynamometer (Type 9275B) employing three-component piezoelectric crystals. Over a regular period, the cutting forces’ average values were stopped.Adigital pyrometer was used to measure the cutting temperature. The average surface roughness (Ra) of the workpiece was determined using a contact-type measurement device (Surftest SJ-210). Data were recorded for each turning operation under varied machining conditions. Results and Discussion This study focuses on the thermal conductivity and viscosity of various vegetable oils at 25 °C, properties that are crucial for determining their suitability in manufacturing applications. Among the tested oils, corn oil exhibited the highest thermal conductivity (0.154 W/mK), indicating its effectiveness in heat transfer, which is vital for maintaining optimal operating temperatures. The thermal conductivity of the different vegetable oils is compared in Fig. 3. Viscosity, which characterizes a fluid’s resistance to flow, is affected by factors such as temperature and molecular structure. Corn oil also exhibited a viscosity of 61 cP (centipoise) at 25 °C, reflecting its Fig. 2. Experimental setup with MQL Fig. 3. Thermal conductivity of different vegetable oils
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology resistance to flow at that temperature. The viscosity of various vegetable oils is shown in Fig. 4. Viscosity plays a crucial role in applications where oils are used to reduce friction and wear between moving components. Oils with higher viscosity generally provide better lubrication and film formation, thereby protecting mechanical components from damage. In metal processing operations, such as machining, where heat generation is unavoidable, the use of corn oil as a cutting fluid can effectively dissipate heat, preventing tool wear and extending tool life. Fig. 4. Viscosity of different vegetable oils Fig. 5. Thermal conductivity of different nanofluids The integration of nanoparticles into corn oil is an effective strategy for minimizing friction due to their superior tribological and thermo-physical characteristics compared to corn oil alone. Nano-lubricants have been shown to exhibit exceptional efficacy, forming a rolling, protective film and promoting mending and polishing effects. Fig. 5 shows the thermal conductivity behavior of nanofluids. Across all nanofluids, the thermal conductivity increases by up to 0.8 % with the incorporation of nanoparticles. However, when the nanoparticle concentration reaches 1 %, a decline occurs because
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 of sedimentation or agglomeration phenomena. Different nanopowders such as CuO, Al2O3, graphene, and multi-walled carbon nanotubes were evaluated across different nanofluids. Among these, graphene nanofluids exhibited the most promising thermal conductivity performance. Compared to corn oil’s thermal conductivity of 0.154 W/mK, graphene oil with a 0.8 % nanoparticle concentration demonstrated an improvement of 9.74 %, reaching 0.169 W/mK. Remarkable fact is that graphene nanofluids exhibited the most promising thermal conductivity performance. In particular, graphene nanofluids consistently outperformed other types, with multi-walled carbon nanotubes following closely, next by copper oxide and aluminum oxide. These findings underscore the remarkable potential of graphene-based nanofluids in enhancing thermal conductivity compared to conventional base fluids. Graphene’s exceptional thermal conductivity is attributed to its unique atomic structure. Graphene consists of a single layer of carbon atoms arranged in a two-dimensional honeycomb lattice, enabling efficient heat transfer due to its high phonon mean free path and ballistic transport of heat carriers. Furthermore, graphene exhibits superior mechanical strength and stability, preventing structural deformations that could impede heat transfer. Its immense surface area allows for easier interaction with neighboring molecules, enhancing heat transfer efficiency. Fig. 6 illustrates the change in viscosity of different nanofluids with the incorporation of different nanoparticles. Across all nanofluids, there is a noticeable increase in viscosity of up to 0.8 % upon the addition of nanoparticles. However, once the nanoparticle concentration reaches 1 %, a decrease in viscosity occurs due to sedimentation or agglomeration phenomena. Various nanopowders, including CuO, Al2O3, graphene, and multi-walled carbon nanotubes, underwent evaluation in different nanofluid formulations. Graphene nanofluids demonstrated the most favorable viscosity performance. In comparison to corn oil’s viscosity of 61 cP, the viscosity of graphene oil with a 0.8 % nanoparticle concentration saw a notable increase of 21.3 %, reaching 74 cP. Remarkably, graphene nanofluids consistently surpassed other types in terms of viscosity enhancement. These results highlight the potential of graphene-based nanofluids in improving viscosity characteristics compared to conventional base fluids because graphene’s inherent robustness minimizes structural deformations within the fluid, thus contributing to enhanced viscosity. High cutting forces lead to rapid tool wear, shortening tool lifespan and increasing the frequency of tool changes, and result in poor surface finish due to vibration and chatter during machining. Various nanopowders, such as CuO, Al2O3, graphene, and multi-walled carbon nanotubes, were evaluated in Fig. 6. Viscosity of different nanofluids
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology nanofluids of different compositions. Fig. 7 illustrates the measured cutting force with varying nanoparticle concentrations (0.2 wt. %, 0.4 wt. %, 0.8 wt. %, and 1 wt. %). Graphene nanofluids provided the most significant reduction in cutting force. Using the base cutting fluid resulted in a cutting force of 135 N; however, with 0.8 wt. % graphene nanofluid, the cutting force decreased to 104 N, i.e. by 29.8 %. This is attributed to improved lubrication; nanoparticles on the metal surface formed a robust lubricant film, leading to better heat dispersion. The higher thermal conductivity and improved lubrication from increased graphene concentration reduced friction and heat generation. At 1 wt. % graphene concentration, the cutting force increased to 108 N compared to 0.8 wt. %, primarily because of nanoparticle agglomeration, which impaired the nanofluid’s performance. Fig. 7. Cutting forces when using different nanofluids The tribological properties of a component determine its ability to effectively and long-term perform its intended function in the intended application area. Surface quality is a key factor influencing tribological characteristics, and low surface roughness is generally preferred. This study investigated the effects of several nanofluids (CuO, Al2O3, graphene, and multi-walled carbon nanotubes) on average surface roughness. Fig. 8 illustrates the measured surface roughness with varying nanoparticle concentrations (0.2 wt. %, 0.4 wt. %, 0.8 wt. %, and 1 wt.%). Graphene nanofluids provided the most significant reduction in surface roughness. Using the base cutting fluid resulted in a surface roughness of 1.18 μm; however, with 0.8 wt. % of graphene nanofluid, the surface roughness decreased to 0.78 μm, i.e. by 51.3 %. This is attributed to improved lubrication; nanoparticles on the metal surface formed a robust lubricant film, leading to better heat dispersion. The higher thermal conductivity and improved lubrication from increased graphene concentration reduced friction and heat generation. However, at 1 wt. % graphene concentration, the surface roughness increased to 0.8 μm compared to 0.8 wt.%, primarily because of nanoparticle agglomeration, which impaired the nanofluid’s performance. Higher cutting temperatures expedite the deterioration of the cutting tool, causing tool materials to soften and wear down, leading to reduced tool life, and can negatively affect surface finish. Extreme cutting temperatures can cause changes in the workpiece material microstructure because of heat generated in the cutting process, affecting properties such as hardness, tensile strength, and residual stresses. This study investigated how different nanofluids affect the average cutting temperature. Fig. 9 illustrates the measured cutting temperature with varying nanoparticle concentrations in nano cutting fluids (0.2 wt. %, 0.4 wt. %, 0.6 wt. %, 0.8 wt. %, and 1 wt. %). Graphene nanofluids provided the most significant reduction in cutting temperature. Using the base cutting fluid resulted in a cutting temperature of 48 °C; however, with
OBRABOTKAMETALLOV technology Vol. 27 No. 1 2025 Fig. 8. Surface roughness when using different nanofluids 0.8 wt. % of graphene nanofluid, the cutting temperature decreased to 31 °C, i.e. by 54.2%. This is attributed to improved lubrication; nanoparticles on the metal surface formed a robust lubricant film, leading to better heat dispersion. The higher thermal conductivity and improved lubrication from increased graphene concentration reduced friction and heat generation. However, at 1 wt. % graphene concentration, the cutting temperature increased to 32 °C compared to 0.8 wt.%, primarily because of nanoparticle agglomeration, which impaired the nanofluid’s performance. Conclusion This study reports on turning experiments on AISI 1014 steel under MQL condition, using five vegetable oils. Corn oil was selected as the base oil, and nanofluids were created by adding CuO, Al2O3, graphene, Fig. 9. Cutting temperature when using different nanofluids
OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology and multi-walled carbon nanotubes to the base oil. The optimal concentration and nanoparticle type were identified. The main findings are summarized below: ● Corn oil significantly affects the thermophysical characteristics such as viscosity and thermal conductivity compared to other vegetable oils. ● Of the four nanoparticle types investigated, graphene nanoparticles provided the greatest reduction in cutting force, temperature, and surface roughness during the turning process. Experimentally, the use of corn oil containing 0.8 wt. % graphene nanoparticles resulted in a cutting force of 104 N, which is 29.8 % less than that of pure corn oil. ● The nanofluid’s effectiveness in reducing cutting force, cutting temperature, and surface roughness decreases at given nanoparticle concentrations (1 wt. %). However, at a high concentration (1 wt. %), the load reduction decreases because of a significant agglomeration of nanoparticles. The optimal nanoparticle concentration in corn oil is 0.8 wt. %. The potential for future research in sustainable machining processes is significant. Means to mitigate environmental damage compared to traditional lubrication methods and lubricants are proposed, and promising developments in economic and social aspects are demonstrated. Expanding the exploration of green nano-cutting fluids (NCF) under MQL, future research could investigate di- and tri-hybrid nanoparticles to enhance the functional properties of cutting fluids, including the development of biosynthesis plant extract routes for nanoparticle preparation, and assess the impact of developed NCF on the performance characteristics of various metals, alloys, and composites during turning. References 1. Ghosh S., Rao P.V. Application of sustainable techniques in metal cutting for enhanced machinability: a review. Journal of Cleaner Production, 2015, vol. 100, pp. 17–34. DOI: 10.1016/j.jclepro.2015.03.039. 2. O’Sullivan D., Cotterell M. Temperature measurement in single point turning. Journal of Materials Processing Technology, 2001, vol. 118 (1–3), pp. 301–308. DOI: 10.1016/S0924-0136(01)00853-6. 3. Waydande R.P., Ghatge D.A. Performance evaluation of cutting parameters for surface roughness & power consumption in turning of 904l stainless steel using vegetable oil based cutting fluids. Advanced Manufacturing and Materials Science: Selected Extended Papers of ICAMMS. Springer, 2018, pp. 317–325. DOI: 10.1007/978-3-31976276-0_32. 4. Cetin M.H., Ozcelik B., Kuram E., Demirbas E. Evaluation of vegetable based cutting fluids with extreme pressure and cutting parameters in turning of AISI 304L by Taguchi method. Journal of Cleaner Production, 2011, vol. 19, pp. 2049–2056. DOI: 10.1016/j.jclepro.2011.07.013. 5. Manikanta J.E.,Ambhore N., Nikhare C.Application of sustainable techniques in grinding process for enhanced machinability: a review. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2024, vol. 46. DOI: 10.1007/s40430-024-04801-5. 6. Katna R., Suhaib M., Agrawal N. Nonedible vegetable oil-based cutting fluids for machining processes – a review. Materials and Manufacturing Processes, 2020, vol. 35 (1), pp. 1–32. DOI: 10.1080/10426914.2019. 1697446. 7. Adler D.P., Hii W.S., Michalek D.J., Sutherland J.W. Examining the role of cutting fluids in machining and efforts to address associated environmental/health concerns. Machining Science and Technology, 2006, vol. 10 (1), pp. 23–58. DOI: 10.1080/10910340500534282. 8. Agrawal S.M., Patil N.G. Experimental study of non edible vegetable oil as a cutting fluid in machining of M2 steel using MQL. Procedia Manufacturing, 2028, vol. 20, pp. 207–212. 9. Sankaranarayanan R., Krolczyk G.M. A comprehensive review on research developments of vegetable-oil based cutting fluids for sustainable machining challenges. Journal of Manufacturing Processes, 2021, vol. 67, pp. 286–313. DOI: 10.1016/j.jmapro.2021.05.002. 10. Sharif M.N., Pervaiz S., Deiab I. Potential of alternative lubrication strategies for metal cutting processes: a review. The International Journal of Advanced Manufacturing Technology, 2017, vol. 89, pp. 2447–2479. DOI: 10.1007/s00170-016-9298-5. 11. Kazeem R.A., Fadare D.A., Akande I.G., Jen T.C., Akinlabi S.A., Akinlabi E.T. Evaluation of crude watermelon oil as lubricant in cylindrical turning of AISI 1525 steel employing Taguchi and grey relational analyses techniques. Heliyon, 2024, vol. 10 (3). DOI: 10.1016/j.heliyon.2024.e25349.
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