Skip to main content
SpringerLink
Log in

Investigating the optimum molybdenum disulfide (MoS2) nanolubrication parameters in CNC milling of AL6061-T6 alloy

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Aluminum 6061-T6 is an important alloy as it has dominant mechanical properties like weldability and hardness, and has the potential to be used at variable temperatures. AL6061-T6 is frequently used in the aerospace industry, as well as aircraft, automotive, and packaging food industries. Milling of Al6061-T6 is important especially to produce various product shapes for adapting to diverse applications. The aptitude of the CNC milling machine for batch production would be a noteworthy advantage. However, the demand for high quality brings attention to product quality, particularly the roughness of the machined surface because of its effect on product appearance, function, and reliability. Introducing correct lubrication to the machining zone could improve the tribological characteristics of Al6061-T6. For additional improvement, applying nanolubrication may produce superior product quality, as the rolling action of billions of nanoparticle units in the tool chip interface can significantly decrease the cutting forces. In this research work, the optimum MoS2 nanolubrication parameters in Al6061-T6 milling to achieve the lowest cutting force, cutting temperature and surface roughness are investigated. The parameters include nanolubricant concentration, nozzle orientation and air carrier pressure. Taguchi optimization along with standard orthogonal array L16(43) are employed. Furthermore, surface roughness and cutting force are analyzed via signal-to-noise (S/N) response analysis and the analysis of variance (Pareto ANOVA) in the hopes of achieving optimum conditions and to determine which process parameters are statistically significant. Finally, optimization improvements are investigated through confirmation tests.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

Reference

  1. Lakshminarayanan A, Balasubramanian V, Elangovan K (2009) Effect of welding processes on tensile properties of AA6061 aluminium alloy joints. Int J Adv Manuf Technol 40:286–296

    Article  Google Scholar 

  2. Shankar MR, Chandrasekar S, Compton WD, King AH (2005) Characteristics of aluminum 6061-T6 deformed to large plastic strains by machining. Mater Sci Eng A 410–411:364–368

    Article  Google Scholar 

  3. Li Y, Liang SY (1999) Cutting force analysis in transient state milling processes. Int J Adv Manuf Technol 15:785–790

    Article  MathSciNet  Google Scholar 

  4. Hsu SM (2004) Nano-lubrication: concept and design. Tribol Int 37:537–545

    Google Scholar 

  5. Lee J, Cho S, Hwang Y, Cho HJ, Lee C, Choi Y, Ku BC, Lee H, Lee B, Kim D, Kim SH (2009) Application of fullerene-added nano-oil for lubrication enhancement in friction surfaces. Tribol Int 42:440–447

    Article  Google Scholar 

  6. Tao X, Jiazheng Z, Kang X (1996) The ball-bearing effect of diamond nanoparticles as an oil additive. J Phys D Appl Phys 29:2932–2937

    Article  Google Scholar 

  7. Lathkar GS, Bas USK (2000) Clean metal cutting process using solid lubricants. In: Proceedings of the 19th AIMTDR conference. Narosa Publishing House IIT Madras, pp 15–31

  8. Reddy NSK, Nouari M, Yang M (2010) Development of electrostatic solid lubrication system for improvement in machining process performance. Int J Mach Tools Manuf 50:789–797

    Article  Google Scholar 

  9. Dilbag S, Rao PV (2008) Performance improvement of hard turning with solid lubricants. Int J Adv Manuf Technol 38:529–535

    Article  Google Scholar 

  10. Sharma VS, Dogra M, Suri NM (2009) Cooling techniques for improved productivity in turning. Int J Mach Tools Manuf 49:435–453

    Article  Google Scholar 

  11. Sreejith PS, Ngoi BKA (2000) Dry machining: machining of the future. J Mater Process Technol 101:287–291

    Article  Google Scholar 

  12. Klocke F, Eisenblätter G (1997) Dry cutting. CIRP Ann Manuf Technol 46:519–526

    Article  Google Scholar 

  13. Lee P, Naam JS, Li C, Lee SW (2012) An experimental study on micro-grinding process with nanofluid minimum quantity lubrication (MQL). Int J Precis Eng Manuf 13(3):331–338

    Article  Google Scholar 

  14. He S (1982) Solid lubrication materials for high temperature: a review. Tribol Int 15:303–314

    Article  Google Scholar 

  15. Miaosun S (2000) Solid lubrication materials. China Chemistry Press, Beijing

    Google Scholar 

  16. Nakamura T, Tanaka S, Hayakawa K, Fukai Y (2000) A study of the lubrication behavior of solid lubricants in the upsetting process. J Tribol 122:803–808

    Article  Google Scholar 

  17. Alberts M, Kalaitzidou K, Melkote S (2009) An investigation of graphite nanoplatelets as lubricant in grinding. Int J Mach Tools Manuf 49:966–970

    Article  Google Scholar 

  18. Deshmukh SD, Basu SK (2006) Significance of solid lubricants in metal cutting, in: 22nd AIMTDR

  19. Sayuti M, Sarhan AAD, Hamdi M (2013) An investigation of optimum SiO2 nanolubrication parameters in end milling of aerospace Al6061-T6 alloy. Int J Adv Manuf Technol 67(1–4):833–849

    Google Scholar 

  20. Keblinski P, Phillpot SR, Choi SUS, Eastman JA (2002) Mechanisms of heat flow in suspensions of nano-sized particles (nanofluids). Int J Heat Mass Transf 45:855–863

    Article  MATH  Google Scholar 

  21. Wang W, Liu K, Jiao M (2007) Thermal and non-Newtonian analysis on mixed liquid–solid lubrication. Tribol Int 40:1067–1074

    Article  MathSciNet  Google Scholar 

  22. Lee JH, Hwang KS, Jang SP, Lee BH, Kim JH, Choi SUS, Choi CJ (2008) Effective viscosities and thermal conductivities of aqueous nanofluids containing low volume concentrations of Al2O3 nanoparticles. Int J Heat Mass Transf 51:2651–2656

    Article  Google Scholar 

  23. Murshed SMS, Leong KC, Yang C (2009) A combined model for the effective thermal conductivity of nanofluids. Appl Therm Eng 29:2477–2483

    Article  Google Scholar 

  24. Masmiati N, Sarhan AAD, Hamdi M (2012) Optimizing the cutting parameters for better surface quality in 2.5D cutting utilizing titanium coated carbide ball end mill. Int J Precis Eng Manuf 13(12):2097–2102

    Article  Google Scholar 

  25. Davis JR (1990) Metals handbook, Vol. 2 — Properties and selection: Nonferrous alloys and special-purpose material, 10th edn. ASM International, Materials Park, OH

  26. Liew WYH (2010) Low-speed milling of stainless steel with TiAlN single-layer and TiAlN/AlCrN nano-multilayer coated carbide tools under different lubrication conditions. Wear 269:617–63

    Google Scholar 

  27. Yan J, Zhang Z, Kriyagawa T (2011) Effect of nano-particle lubrication in diamond turning of reaction-bonded SiC. Int J Autom Technol 5:307–312

    Google Scholar 

  28. Hung TC, Su YT (2006) A method for reducing tool wear in a polishing process. Int J Mach Tools Manuf 46:413–423

    Google Scholar 

  29. Wu YY, Tsui WC, Liu TC (2007) Experimental analysis of tribological properties of lubricating oils with nanoparticle additives. Wear 262:819–825

    Google Scholar 

  30. Mu-Jung Kao CRL (2009) Evaluating the role of spherical titanium oxide nanoparticles in reducing friction between two pieced of cast iron. J Alloys Compd 483:456–459

  31. Sarhan AAD, Sayuti M, Hamdi M (2012) Reduction of power and lubricant oil consumption in milling process using a new SiO2 nanolubrication system. Int J Adv Manuf Technol 63(5–8):505–512

    Article  Google Scholar 

  32. Yousefi YIR (2000) A study on ultra-high-speed cutting of aluminium alloy: formation of welded metal on the secondary cutting edge of the tool and its effects on the quality of finished surface. J Int Soc Precis Eng Nanotechnol 24:371–376

    Google Scholar 

  33. N Suresh Kumar Reddy, P Venkateswara Rao (2006) Experimental investigation to study the effect of solid lubricants on cutting forces and surface quality in end milling. Int J Mach Tools Manuf 46:189–198

    Google Scholar 

  34. Sayuti M, Sarhan AAD, Tanaka T, Hamdi M, Saito Y (2013) Cutting force reduction and surface quality improvement in machining of aerospace duralumin AL-2017-T4 using carbon onion nanolubrication system. Int J Adv Manuf Technol 65(9–12):1493–1500

    Article  Google Scholar 

  35. Wakabayashi SST, Inasaki I, Terasaka K, Musha Y, Toda Y (2007) Tribological action and cutting performance of MQL media in machining of aluminium. Ann CIRP 56/1

  36. Lin HSYC (2004) Limitations on use of ZDDP as an antiwear additive in boundary lubrication. Tribol Int 37:25–33

    Google Scholar 

  37. Prado LEMRA, Shindo DJ, Soto KF (2001) Tool wear in the friction-stir welding of aluminium alloy 6061 + 20% Al2O3: a preliminary study. Scr Mater 45:75–80

    Google Scholar 

  38. Hamdan AA, Sarhan AAD, Hamdi M (2012) An optimization method of the machining parameters in high speed machining of stainless steel using coated carbide tool for best surface finish. Int J Adv Manuf Technol 58(1):81–91

    Article  Google Scholar 

  39. Rapoport ONL, Lapsker I, Verdyan A, Moshkovich A, Feldman Y, Tenne R (2005) Behavior of fullerene-like WS2 nanoparticles under severe contact conditions. Wear 259:703–707

    Google Scholar 

  40. Rapoport VLL, Lvovsky M, Nepomnyashchy O, Volovik Y, Tenne R (2002) Mechanism of friction of fullerenes. Ind Lubr Tribol 54:171–176

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Centre of Advanced Manufacturing and Material Processing, Department of Design and Manufacturing, Engineering Faculty, University of Malaya, 50603, Kuala Lumpur, Malaysia

    Bizhan Rahmati, Ahmed A. D. Sarhan & M. Sayuti

  2. Department of Mechanical Engineering, Engineering Faculty, Tehran University, Tehran, Iran

    Bizhan Rahmati

  3. Department of Mechanical Engineering, Faculty of Engineering, Assiut University, Assiut, 71516, Egypt

    Ahmed A. D. Sarhan

Authors
  1. Bizhan Rahmati
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ahmed A. D. Sarhan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. M. Sayuti
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Bizhan Rahmati.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Rahmati, B., Sarhan, A.A.D. & Sayuti, M. Investigating the optimum molybdenum disulfide (MoS2) nanolubrication parameters in CNC milling of AL6061-T6 alloy. Int J Adv Manuf Technol 70, 1143–1155 (2014). https://doi.org/10.1007/s00170-013-5334-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-013-5334-x

Keywords

Search

Navigation