Performance evaluation of nanofluid-based minimum quantity lubrication grinding of Ni-Cr alloy under the influence of CuO nanoparticles

doi:10.1007/s40436-021-00362-1

Abstract

Abstract: In machining processes, researchers are actively engaged in exploring minimum quantity lubrication (MQL) as a possible alternative to traditional flood cooling owing to economic and ecological concerns. The search for ecologically safe lubricants has attracted the attention of scientists looking to use vegetable oil as a lubricant. The nanofluid MQL technique with biodegradable oils as the base is a relatively new method with the potential to replace mineral oils. In the present study, the grinding of Inconel-718 alloy was investigated using nanofluid MQL (NFMQL) with biodegradable oils as the base. Nanofluids are composed by dispersing 0.5% (mass fraction) and 1% (mass fraction) of CuO nanoparticles in vegetable oil. The surface morphology, G-ratio, forces, and grinding energy were examined under pure MQL, NFMQL, and dry and flood lubrication conditions. The experimental results indicated that the nanofluid MQL significantly improved the machining performance. Owing to the polishing and rolling effect of nanoparticles on the tool work interface, a surface finish under a 0.5% (mass fraction) nanofluid was found to be better than pure MQL-dry and flood lubrication conditions. The NFMQL technique with 1% (mass fraction) CuO nanoparticles with palm oil as the base helped in achieving a better evacuation of chips from the grinding zone, leading to a better surface finish with a high material removal rate along with less energy consumption compared to flood and dry grinding.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-021-00362-1

Key words: Minimum quantity lubrication (MQL), Nanoparticles, Grinding, Vegetable oils, Inconel-718 alloy

Roshan Lal Virdi, Sukhpal Singh Chatha, Hazoor Singh. Performance evaluation of nanofluid-based minimum quantity lubrication grinding of Ni-Cr alloy under the influence of CuO nanoparticles[J]. Advances in Manufacturing, 2021, 9(4): 580-591.

TrendMD

References

1. Sadeghi MH, Hadad MJ, Tawakoli T et al (2010) An investigation on surface grinding of AISI 4140 hardened steel using minimum quantity lubrication-MQL technique. Int J Mater Form 3(4):241-251
2. Malkin S, Guo C (2007) Thermal analysis of grinding. CIRP Ann 56(2):760-782
3. Fang N, Wu Q (2009) A comparative study of the cutting forces in high speed machining of Ti-6Al-4V and Inconel 718 with a round cutting edge tool. J Mater Process Technol 209(9):4385-4389
4. Li CH, Hou YL, Xiu SC et al (2008) Application of lubrication theory to near-dry green grinding-feasibility analysis. Adv Mater Res 44/46:135-142
5. Silva LR, Bianchi EC, Catai RE et al (2005) Study on the behavior of the minimum quantity lubricant-MQL technique under different lubricating and cooling conditions when grinding ABNT 4340 steel. J Braz Soc Mech Sci Eng 27:192-199
6. Naveena B, Mariyam Thaslima SS, Savitha V et al (2017) Simplified MQL system for drilling AISI 304 SS using cryogenically treated drills. Mater Manuf Process 32(15):1679-1684
7. Ozcelik B, Kuram E, Huseyin Cetin M et al (2011) Experimental investigations of vegetable based cutting fluids with extreme pressure during turning of AISI 304L. Tribol Int 44(12):1864-1871
8. Sharma VS, Singh G, Sørby K (2015) A review on minimum quantity lubrication for machining processes. Mater Manuf Process 30(8):935-953
9. Ni C, Zhu L (2020) Investigation on machining characteristics of TC4 alloy by simultaneous application of ultrasonic vibration assisted milling (UVAM) and economical-environmental MQL technology. J Mater Process Technol 278:116518. https://doi.org/10.1016/j.jmatprotec.2019.116518
10. Lawal SA, Choudhury IA, Nukman Y (2014) Evaluation of vegetable and mineral oil-in-water emulsion cutting fluids in turning AISI 4340 steel with coated carbide tools. J Clean Prod 66:610-618
11. Das SK, Putra N, Thiesen P et al (2003) Temperature dependence of thermal conductivity enhancement for nanofluids. J Heat Transf 125(4):567-574
12. Kalita P, Malshe AP, Arun KS et al (2012) Study of specific energy and friction coefficient in minimum quantity lubrication grinding using oil-based nanolubricants. J Manuf Process 14(2):160-166
13. Virdi RL, Singh Chatha S, Singh H (2020) Performance evaluation of Inconel 718 under vegetable oils based nanofluids using minimum quantity lubrication grinding. Mater Today Proc 33(3):1528-1545
14. Setti D, Sinha MK, Ghosh S et al (2015) Performance evaluation of Ti-6Al-4V grinding using chip formation and coefficient of friction under the influence of nanofluids. Int J Mach Tools Manuf 88:237-248
15. Tawakoli T, Hadad MJ, Sadeghi MH (2010) Influence of oil mist parameters on minimum quantity lubrication-MQL grinding process. Int J Mach Tools Manuf 50(6):521-531
16. Mao C, Tang X, Zou H et al (2012) Investigation of grinding characteristic using nanofluid minimum quantity lubrication. Int J Precis Eng Manuf 13(10):1745-1752
17. Holmberg K, Siilasto R, Laitinen T et al (2013) Global energy consumption due to friction in paper machines. Tribol Int 62:58-77
18. Shashidhara YM, Jayaram SR (2010) Vegetable oils as a potential cutting fluid-an evolution. Tribol Int 43(5/6):1073-1081
19. Marques A, Paipa Suarez M, Falco SW et al (2019) Turning of Inconel 718 with whisker-reinforced ceramic tools applying vegetable-based cutting fluid mixed with solid lubricants by MQL. J Mater Process Technol 266:530-543
20. Krajnik P, Pusavec F, Rashid A (2011) Nanofluids:properties, applications and sustainability aspects in materials processing technologies. In:Advances in sustainable manufacturing. Springer, Berlin, pp 107-113
21. Su Y, Gong L, Chen D (2015) An investigation on tribological properties and lubrication mechanism of graphite nanoparticles as vegetable based oil additive. J Nanomater 2015:1-7
22. Wang X, Li C, Zhang Y et al (2020) Vegetable oil-based nanofluid minimum quantity lubrication turning:academic review and perspectives. J Manuf Process 59:76-97
23. Yang M, Li C, Zhang Y et al (2019) Effect of friction coefficient on chip thickness models in ductile-regime grinding of zirconia ceramics. Int J Adv Manuf Technol 102(5):2617-2632
24. Silva LR (2013) Environmentally friendly manufacturing:behavior analysis of minimum quantity of lubricant-MQL in grinding process. J Clean Prod 256:103287. https://doi.org/10.1016/j.jclepro.2013.01.033
25. Shokoohi Y, Khosrojerdi E, Rassolian SB (2015) Machining and ecological effects of a new developed cutting fluid in combination with different cooling techniques on turning operation. J Clean Prod 94:330-339
26. Hadad M, Hadi M (2013) An investigation on surface grinding of hardened stainless steel S34700 and aluminum alloy AA6061 using minimum quantity of lubrication (MQL) technique. Int J Adv Manuf Technol 68:2145-2158
27. Zhang Y, Li C, Jia D et al (2016) Experimental study on the effect of nanoparticle concentration on the lubricating property of nanofluids for MQL grinding of Ni-based alloy. J Mater Process Technol 232:100-115
28. Gao T, Li C, Zhang Y et al (2019) Dispersing mechanism and tribological performance of vegetable oil-based CNT nanofluids with different surfactants. Tribol Int 131:51-63
29. Guo S, Li C, Zhang Y et al (2017) Experimental evaluation of the lubrication performance of mixtures of castor oil with other vegetable oils in MQL grinding of nickel-based alloy. J Clean Prod 140(Part 3):1060-1076
30. Thottackkad MV, Perikinalil RK, Kumarapillai PN (2012) Experimental evaluation on the tribological properties of coconut oil by the addition of CuO nanoparticles. Int J Precis Eng Manuf 13(1):111-116
31. Shabgard M, Seyedzavvar M, Mohammadpourfard M (2017) Experimental investigation into lubrication properties and mechanism of vegetable-based CuO nanofluid in MQL grinding. Int J Adv Manuf Technol 92(9):3807-3823
32. Wang Y, Li C, Zhang Y et al (2017) Experimental evaluation on tribological performance of the wheel/workpiece interface in minimum quantity lubrication grinding with different concentrations of Al₂O₃ nanofluids. J Clean Prod 142(Part 4):3571-3583
33. Choi SUS, Zhang ZG, Yu W et al (2001) Anomalous thermal conductivity enhancement in nanotube suspensions. Appl Phys Lett 79(14):2252. https://doi.org/10.1063/1.1408272
34. Seyedzavvar M, Abbasi H, Kiyasatfar M et al (2020) Investigation on tribological performance of CuO vegetable-oil based nanofluids for grinding operations. Adv Manuf 8(3):344-360
35. Wang Y, Li C, Zhang Y et al (2016) Experimental evaluation of the lubrication properties of the wheel/workpiece interface in MQL grinding with different nanofluids. Tribol Int 99:198-210
36. Zhang Y, Li C, Yang M et al (2016) Experimental evaluation of cooling performance by friction coefficient and specific friction energy in nanofluid minimum quantity lubrication grinding with different types of vegetable oil. J Clean Prod 139:685-705
37. Banerjee N, Sharma A (2019) Improving machining performance of Ti-6Al-4V through multi-point minimum quantity lubrication method. Proc Inst Mech Eng Part B J Eng Manuf 233(1):321-336
38. Emami M, Sadeghi MH, Sarhan AAD et al (2014) Investigating the minimum quantity lubrication in grinding of Al₂O₃ engineering ceramic. J Clean Prod 66:632-643
39. Ogonowski S, Wołosiewicz-Głąb M, Ogonowski Z et al (2018) Comparison of wet and dry grinding in electromagnetic mill. Minerals 8(4):138-157
40. Tawakoli T, Hadad MJ, Sadeghi MH (2010) Investigation on minimum quantity lubricant-MQL grinding of 100Cr6 hardened steel using different abrasive and coolant-lubricant types. Int J Mach Tools Manuf 50(8):698-708
41. Wang Y, Li C, Zhang Y et al (2016) Experimental evaluation of the lubrication properties of the wheel/workpiece interface in minimum quantity lubrication (MQL) grinding using different types of vegetable oils. J Clean Prod 127:487-499
42. Reddy NSK, Nouari M, Yang M (2010) Development of electrostatic solid lubrication system for improvement in machining process performance. Int J Mach Tools Manuf 50(9):789-797
43. Shen B, Shih AJ, Tung SC (2008) Application of nanofluids in minimum quantity lubrication grinding. Tribol Trans 51(6):730-737
44. Jia D, Li C, Zhang Y et al (2017) Specific energy and surface roughness of minimum quantity lubrication grinding Ni-based alloy with mixed vegetable oil-based nanofluids. Precis Eng 50:248-262
45. Tawakoli T, Hadad M, Sadeghi MH et al (2011) Minimum quantity lubrication in grinding:effects of abrasive and coolant-lubricant types. J Clean Prod 19(17/18):2088-2099
46. Wang Y, Li C, Zhang Y et al (2018) Processing characteristics of vegetable oil-based nanofluid MQL for grinding different workpiece materials. Int J Precis Eng Manuf Green Technol 5(2):327-339
47. Zhang X, Li C, Zhang Y et al (2017) Lubricating property of MQL grinding of Al₂O₃/SiC mixed nanofluid with different particle sizes and microtopography analysis by cross-correlation. Precis Eng 47:532-545
48. Rapeti P, Pasam VK, Rao Gurram KM et al (2018) Performance evaluation of vegetable oil based nano cutting fluids in machining using grey relational analysis-a step towards sustainable manufacturing. J Clean Prod 172:2862-2875
49. Shaw MC, Pigott JD, Richardson LP (1951) Effect of cutting fluid upon chip-tool interface temperature. Trans. ASME 71:45-56

[1]	Yu-Xiang Song, Chang-He Li, Zong-Ming Zhou, Bo Liu, Shubham Sharma, Yusuf Suleiman Dambatta, Yan-Bin Zhang, Min Yang, Teng Gao, Ming-Zheng Liu, Xin Cui, Xiao-Ming Wang, Wen-Hao Xu, Run-Ze Li, Da-Zhong Wang. Nanobiolubricant grinding: a comprehensive review [J]. Advances in Manufacturing, 2025, 13(1): 1-42.
[2]	Xiao-Fei Lei, Wen-Feng Ding, Biao Zhao, Chuan Qian, Zi-Ang Liu, Qi Liu, Dong-Dong Xu, Yan-Jun Zhao, Jian-Hui Zhu. Grinding of particle-reinforced metal matrix composite materials: current status and prospects [J]. Advances in Manufacturing, 2025, 13(1): 43-68.
[3]	Xiao-Fei Lei, Wen-Feng Ding, Biao Zhao, Dao-Hui Xiang, Zi-Ang Liu, Chuan Qian, Qi Liu, Dong-Dong Xu, Yan-Jun Zhao, Jian-Hui Zhu. Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation [J]. Advances in Manufacturing, 2025, 13(1): 88-104.
[4]	Yu-Long Wang, Yan-Bin Zhang, Xin Cui, Xiao-Liang Liang, Run-Ze Li, Ruo-Xin Wang, Shubham Sharma, Ming-Zheng Liu, Teng Gao, Zong-Ming Zhou, Xiao-Ming Wang, Yusuf Suleiman Dambatta, Chang-He Li. High-speed grinding: from mechanism to machine tool [J]. Advances in Manufacturing, 2025, 13(1): 105-154.
[5]	Chong-Jun Wu, Fei Liu, Jia-Zhou Wen, Pei-Yun Xia, Steven Y. Liang. Grinding defect characteristics and removal mechanism of unidirectional C_f/SiC composites [J]. Advances in Manufacturing, 2025, 13(1): 211-228.
[6]	Jin-Hao Wang, Lu Wang, Han-Song Li, Ning-Song Qu. Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation [J]. Advances in Manufacturing, 2025, 13(1): 229-244.
[7]	Jia-Hao Liu, Dong-Zhou Jia, Chang-He Li, Yan-Bin Zhang, Ying Fu, Zhen-Lin Lv, Shuo Feng. Mechanism and machinability in novel electroplastic-assisted grinding ductile iron [J]. Advances in Manufacturing, 2025, 13(1): 245-263.
[8]	Zhao-Qing Zhang, Kai-Ning Shi, Yao-Yao Shi, Yi-Hui Song, Zhe He, Ya-Song Pu. Study on a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding [J]. Advances in Manufacturing, 2024, 12(2): 288-299.
[9]	Cheng Fan, Cao-Yang Xue, Jun Zhao, Wei Jiang, Wen-Ge Han, Lei Zhang, Li-Ning Sun. Process planning and contour-based error compensation for precision grinding of miniature scalpels [J]. Advances in Manufacturing, 2024, 12(1): 108-123.
[10]	Zi-Shan Ding, Yun-Hui Zhao, Miao-Xian Guo, Wei-Cheng Guo, Chong-Jun Wu, Steven Y. Liang. An iterative blending integrating grinding force model considering grain size and dislocation density evolution [J]. Advances in Manufacturing, 2023, 11(3): 428-443.
[11]	Ben-Kai Li, Biao Zhao, Wen-Feng Ding, Yu-Can Fu, Chang-He Li, Rong Wang, Yan-Jun Zhao. CBN grain wear and its effects on material removal during grinding of FGH96 powder metallurgy superalloy [J]. Advances in Manufacturing, 2023, 11(1): 21-38.
[12]	Bing Cao, Guo-Long Li, Alessandro Fortunato, Heng-Xin Ni. Continuous generating grinding method for beveloid gears and analysis of grinding characteristics [J]. Advances in Manufacturing, 2022, 10(3): 459-478.
[13]	Ming-Hui Fang, Tao Yu, Feng-Feng Xi. Effect of back pressure on the grinding performance of abrasive suspension flow machining [J]. Advances in Manufacturing, 2022, 10(1): 143-157.
[14]	Xiang-Long Zhu, Yu Li, Zhi-Gang Dong, Ren-Ke Kang, Shang Gao. Study into grinding force in back grinding of wafer with outer rim [J]. Advances in Manufacturing, 2020, 8(3): 361-368.
[15]	Ben-Kai Li, Qing Miao, Min Li, Xi Zhang, Wen-Feng Ding. An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels [J]. Advances in Manufacturing, 2020, 8(2): 160-176.