Skip to main content

Advertisement

SpringerLink
Log in

Ti6Al4V grinding using different lubrication modes for minimizing energy consumption

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

Abstract

To create high-performance cutting fluids, it has been suggested to make use of nanofluids, provided that these fluids are devoid of potentially harmful contaminants and that they possess adequate lubricating and cooling properties. Both the production of a graphene nanoplatelet-based nanofluid from palm oil and the testing of this nanofluid were carried out with the assistance of minimum quantity lubrication. Significant improvements have been made to both the anti-wear capabilities of the Ti6Al4V/ZrO2 tribo-anti-friction pair as well as the nanofluid/minimum quantity lubrication mode, which is founded on palm oil. Specific cutting energy was found to be lowered by 93.49% when utilizing a nanofluid composed of graphene nanoplatelets at a weight concentration of 0.1% compared to dry circumstances, and by 90.889% when using commercially available high-performance minimum quantity lubrication. To achieve these outcomes, a graphene nanoplatelet-based nanofluid with a concentration of only 0.1% by weight was used. Grinding cutting forces were reduced by using a nanofluid containing 0.1% by weight of graphene nanoplatelets.

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

Fig. 1
Fig. 2 
Fig. 3 
Fig. 4 
Fig. 5
Fig. 6 
Fig. 7 
Fig. 8 
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Data availability

The paper contains the necessary information as well as the data.

Code availability

Not relevant.

Abbreviations

MQL:

Minimum quantity lubrication

PO:

Palm oil

PO/MQL:

Palm oil/minimum quantity lubrication

SPIF:

Single point incremental forming

MoS2:

Molybdenum disulfide

hBN:

Hexagonal boron nitride

CryoMQL:

Cryogenic minimum quantity lubrication

Al2O3:

Aluminum dioxide

MWCNT:

Multiwall carbon nanotubes

MOORA:

Modified overall rank ordering

AHP:

Analytic hierarchy process

GNP:

Graphene nanoplatelets

CA:

Contact angle

References

  1. Hernández González L, Seid Ahmed Y, Pérez Rodríguez R, Zambrano Robledo P, Guerrero Mata M (2018) Selection of machining parameters using a correlative study of cutting tool wear in high-speed turning of AISI 1045 steel. J Manuf Mater Process 2(4):66. https://doi.org/10.3390/jmmp2040066

    Article  Google Scholar 

  2. Seid Ahmed Y, Ryon A (2022) Tribological performance of a hybrid CryoMQL system on Ti6Al4V milling. Int J Adv Manuf Technol 120(11–12):8185–8199. https://doi.org/10.1007/S00170-022-09249-2/FIGURES/11

    Article  Google Scholar 

  3. Khalil K, Mohd A, Mohamad COC, Faizul Y, Ariffi SZ (2021) The Optimization of Machining Parameters on Surface Roughness for AISI D3 Steel. J Phys Conf Ser. https://doi.org/10.1088/1742-6596/1874/1/012063

  4. Diniz AE, Machado ÁR, Corrêa JG (2016) Tool wear mechanisms in the machining of steels and stainless steels. Int J Adv Manuf Technol 87(9–12):3157–3168. https://doi.org/10.1007/s00170-016-8704-3

    Article  Google Scholar 

  5. Ayed Y, Germain G, Ammar A, Furet B (2013) Experimental study of tool wear mechanisms in conventional and high pressure coolant assisted machining of titanium alloy Ti17. Key Eng Mater 554–557:1961–1966. https://doi.org/10.4028/www.scientific.net/KEM.554-557.1961

    Article  Google Scholar 

  6. Kawade P, Bokade S (2022) Review of cooling techniques used in metal cutting processes. Advances in Materials and Processing Technologies. https://doi.org/10.1080/2374068X.2022.2109668

  7. Şirin Ş, Kıvak T (2021) Effects of hybrid nanofluids on machining performance in MQL-milling of Inconel X-750 superalloy. J Manuf Process 70:163–176. https://doi.org/10.1016/J.JMAPRO.2021.08.038

    Article  Google Scholar 

  8. Kumar Mishra S, Ghosh S, Aravindan S (2020) Machining performance evaluation of Ti6Al4V alloy with laser textured tools under MQL and nano-MQL environments. J Manuf Process 53:174–189. https://doi.org/10.1016/J.JMAPRO.2020.02.014

    Article  Google Scholar 

  9. Paulo Davim J (2010) Sustainable manufacturing, p 246. [Online]. Available: https://www.wiley.com/en-us/Sustainable+Manufacturing-p-9781848212121. Accessed: Feb. 20, 2023

  10. Davim JP (2013) Green manufacturing processes and systems. Springer. https://doi.org/10.1007/978-3-642-33792-5

  11. Carou D, Rubio EM, Davim JP (2015) A note on the use of the minimum quantity lubrication (MQL) system in turning. Ind Lubr Tribol 67(3):256–261. https://doi.org/10.1108/ILT-07-2014-0070/FULL/XML

    Article  Google Scholar 

  12. Bruschi S, Pezzato L, Ghiotti A, Dabalà M, Bertolini R (2019) Effectiveness of using low-temperature coolants in machining to enhance durability of AISI 316L stainless steel for reusable biomedical devices. J Manuf Process 39(March):295–304. https://doi.org/10.1016/j.jmapro.2019.02.003

    Article  Google Scholar 

  13. Sílvia RC, Lauro CH, Ana H, Davim JP (2022) Development of FEM-based digital twins for machining difficult-to-cut materials: a roadmap for sustainability. J Manuf Process 75:739–766. https://doi.org/10.1016/J.JMAPRO.2022.01.027

    Article  Google Scholar 

  14. López De Lacalle LN, Angulo C, Lamikiz A, Sánchez JA (2006) Experimental and numerical investigation of the effect of spray cutting fluids in high speed milling. J Mater Process Technol 172(1):11–15. https://doi.org/10.1016/J.JMATPROTEC.2005.08.014

    Article  Google Scholar 

  15. Şen N, Şirin Ş, Kıvak T, Civek T, Seçgin Ö (2022) A new lubrication approach in the SPIF process: evaluation of the applicability and tribological performance of MQL. Tribol Int 171:107546. https://doi.org/10.1016/J.TRIBOINT.2022.107546

    Article  Google Scholar 

  16. Yücel A et al (2021) Influence of MoS2 based nanofluid-MQL on tribological and machining characteristics in turning of AA 2024 T3 aluminum alloy. J Market Res 15:1688–1704. https://doi.org/10.1016/J.JMRT.2021.09.007

    Article  Google Scholar 

  17. Sarıkaya M, Şirin Ş, Yıldırım ÇV, Kıvak T, Gupta MK (2021) Performance evaluation of whisker-reinforced ceramic tools under nano-sized solid lubricants assisted MQL turning of Co-based Haynes 25 superalloy. Ceram Int 47(11):15542–15560. https://doi.org/10.1016/J.CERAMINT.2021.02.122

    Article  Google Scholar 

  18. Padhan S, Das A, Santoshwar A, Dharmendrabhai TR, Das SR (2020) Sustainability assessment and machinability investigation of austenitic stainless steel in finish turning with advanced ultra-hard SiAlON ceramic tool under different cutting environments. SILICON 13(1):119–147. https://doi.org/10.1007/S12633-020-00409-1

    Article  Google Scholar 

  19. Sahoo SP, Datta S (2020) Dry, MQL, and nanofluid MQL machining of Ti–6Al–4V using uncoated WC–Co insert: application of jatropha oil as base cutting fluid and graphene nanoplatelets as additives. Arab J Sci Eng 45(11):9599–9618. https://doi.org/10.1007/S13369-020-04849-0/FIGURES/12

    Article  Google Scholar 

  20. Hegab H, Umer U, Soliman M, Kishawy HA (2018) Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718. Int J Adv Manuf Technol 96(9):3449–3458. https://doi.org/10.1007/S00170-018-1825-0

    Article  Google Scholar 

  21. Naresh Babu M, Anandan V, Muthukrishnan N, Arivalagar AA, Dinesh Babu M (2019) Evaluation of graphene based nano fluids with minimum quantity lubrication in turning of AISI D3 steel. SN Appl Sci 1(10):1–15. https://doi.org/10.1007/S42452-019-1182-0/TABLES/8

    Article  Google Scholar 

  22. Hsiao TC, Vu NC, Tsai MC, Dang XP, Huang SC (2021) Modeling and optimization of machining parameters in milling of INCONEL-800 super alloy considering energy, productivity, and quality using nanoparticle suspended lubrication. Meas Control (U K) 54(5–6):880–894. https://doi.org/10.1177/0020294020925842/ASSET/IMAGES/LARGE/10.1177_0020294020925842-FIG2.JPEG

    Article  Google Scholar 

  23. Amrita M, Srikant R, Venkataramana R (2020) Optimisation of cutting parameters for cutting temperature and tool wear in turning AISI4140 under different cooling conditions. Advances in Materials and Processing Technologies. https://doi.org/10.1080/2374068X.2020.1795794

  24. Sen B, Gupta MK, Mia M, Mandal UK, Mondal SP (2020) Wear behaviour of TiAlN coated solid carbide end-mill under alumina enriched minimum quantity palm oil-based lubricating condition. Tribol Int 148:106310. https://doi.org/10.1016/J.TRIBOINT.2020.106310

    Article  Google Scholar 

  25. Pereira O, Martín-Alfonso JE, Rodríguez A, Calleja A, Fernández-Valdivielso A, López de Lacalle LN (2017) Sustainability analysis of lubricant oils for minimum quantity lubrication based on their tribo-rheological performance. J Clean Prod 164:1419–1429. https://doi.org/10.1016/J.JCLEPRO.2017.07.078

    Article  Google Scholar 

  26. Pereira O, Rodríguez A, Fernández-Abia AI, Barreiro J, López de Lacalle LN (2016) Cryogenic and minimum quantity lubrication for an eco-efficiency turning of AISI 304. J Clean Prod 139:440–449. https://doi.org/10.1016/J.JCLEPRO.2016.08.030

    Article  Google Scholar 

  27. Kulandaivel A, Santhanam SK (2020) Experimental investigation on turning of monel k500 alloy using nano graphene cutting fluid under minimum quantity lubrication. ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE). https://doi.org/10.1080/10910344.2020.1765179

  28. Kulandaivel A, Santhanam SK (2020) Experimental investigation on turning of Monel K500 alloy using nano graphene cutting fluid under minimum quantity lubrication. ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE), vol. 2A-2019. https://doi.org/10.1115/IMECE2019-10056

  29. Patole PB, Pol GJ, Desai AA, Kamble SB (2021) Analysis of surface roughness and cutting force under MQL turning using nano fluids. Mater Today Proc 45:5684–5688. https://doi.org/10.1016/J.MATPR.2021.02.501

    Article  Google Scholar 

  30. Elsheikh AH, Elaziz MA, Das SR, Muthuramalingam T, Lu S (2021) A new optimized predictive model based on political optimizer for eco-friendly MQL-turning of AISI 4340 alloy with nano-lubricants. J Manuf Process 67:562–578. https://doi.org/10.1016/J.JMAPRO.2021.05.014

    Article  Google Scholar 

  31. Gaurav G, Sharma A, Dangayach GS, Meena ML (2020) Assessment of jojoba as a pure and nano-fluid base oil in minimum quantity lubrication (MQL) hard-turning of Ti–6Al–4V: A step towards sustainable machining. J Clean Prod 272:122553. https://doi.org/10.1016/J.JCLEPRO.2020.122553

    Article  Google Scholar 

  32. Musavi SH, Davoodi B, Niknam SA (2019) Effects of reinforced nanofluid with nanoparticles on cutting tool wear morphology. J Central S Univ 26(5):1050–1064. https://doi.org/10.1007/S11771-019-4070-2

    Article  Google Scholar 

  33. Sarma D, Borah J, Chandrasekaran M (2021) Multi optimization of nano fluid based machining of titanium alloy: a green manufacturing approach. Mater Today Proc 46:8921–8926. https://doi.org/10.1016/J.MATPR.2021.05.362

    Article  Google Scholar 

  34. Jamil M et al (2019) Effects of hybrid Al2O3-CNT nanofluids and cryogenic cooling on machining of Ti–6Al–4V. Int J Adv Manuf Technol 102(9):3895–3909. https://doi.org/10.1007/S00170-019-03485-9

    Article  Google Scholar 

  35. Zan Z, Guo K, Sun J, Wei X, Tan Y, Yang B (2021) Investigation of MQL parameters in milling of titanium alloy. Int J Adv Manuf Technol 116(1–2):375–388. https://doi.org/10.1007/S00170-021-07441-4/METRICS

    Article  Google Scholar 

  36. Gupta MK, Mia M, Singh GR, Pimenov DY, Sarikaya M, Sharma VS (2018) Hybrid cooling-lubrication strategies to improve surface topography and tool wear in sustainable turning of Al 7075–T6 alloy. Int J Adv Manuf Technol 101(1):55–69. https://doi.org/10.1007/S00170-018-2870-4

    Article  Google Scholar 

  37. Venkatesan K (2022) Machining of different superalloys under MQL using hBN nanofluids. Advances in Materials and Processing Technologies. https://doi.org/10.1080/2374068X.2022.2133720

  38. Stephen DS, Sethuramalingam P (2022) Optimization of grinding titanium with 2%CNT-CBN wheel using TOPSIS. 37(14):1679–1690. https://doi.org/10.1080/10426914.2022.2039696

  39. Chen H, Yu T, Dong J, Zhao Y, Zhao J (2019) Kinematic simulation of surface grinding process with random cBN grain model. Int J Adv Manuf Technol 100(9–12):2725–2739. https://doi.org/10.1007/S00170-018-2840-X/METRICS

    Article  Google Scholar 

  40. Seid Ahmed Y, DePaiva JM, Amorim FL, Torres RD, de Rossi W, Veldhuis SC (2021) Laser surface texturing and characterization of austenitic stainless steel for the improvement of its surface properties. Int J Adv Manuf Technol 115(5–6):1795–1808. https://doi.org/10.1007/s00170-021-07284-z

    Article  Google Scholar 

  41. Ahmed YS, Paiva JM, Arif AFM, Amorim FL, Torres RD, Veldhuis SC (2020) The effect of laser micro-scale textured tools on the tool-chip interface performance and surface integrity during austenitic stainless-steel turning. Appl Surf Sci 510(January):145455. https://doi.org/10.1016/j.apsusc.2020.145455

    Article  Google Scholar 

  42. Rahim EA, Sasahara H (2011) A study of the effect of palm oil as MQL lubricant on high speed drilling of titanium alloys. Tribol Int 44(3):309–317. https://doi.org/10.1016/j.triboint.2010.10.032

    Article  Google Scholar 

  43. Arun A, Rameshkumar K, Unnikrishnan D, Sumesh A (2018) Tool condition monitoring of cylindrical grinding process using acoustic emission sensor. Mater Today Proc 5(5):11888–11899. https://doi.org/10.1016/j.matpr.2018.02.162

    Article  Google Scholar 

  44. Davim JP (2011) Tribology for engineers: A practical guide. WoodHead Publishing in Mechanical Engineering

  45. Jackson MJ, Davim JP (eds) (2010) Machining with abrasives. Springer. https://doi.org/10.1007/978-1-4419-7302-3

  46. Liu C, Wan M, Zhang W, Yang Y (2021) Chip formation mechanism of Inconel 718: a review of models and approaches. Chin J Mech Eng 34(1):1–16. https://doi.org/10.1186/S10033-021-00552-9

    Article  Google Scholar 

  47. Yu W, Li Y, Chen J, Zuo Z, Chen D, An Q, Chen M, Wang H (2020) Experimental study on chip formation and surface quality in milling of TiB2/Al alloy composites. Mater Manuf Process. https://doi.org/10.1080/10426914.2020.1779937

  48. Ducobu F, Rivière-Lorphèvre E, Filippi E (2015) Experimental contribution to the study of the Ti6Al4V chip formation in orthogonal cutting on a milling machine. IntJ Mater Form 3(8):455–468. https://doi.org/10.1007/S12289-014-1189-4

    Article  Google Scholar 

  49. Carvalho S, Horovistiz A, Davim JP (2023) Morphological characterization of chip segmentation in Ti-6Al-7Nb machining: a novel method based on digital image processing. Measurement 206:112330. https://doi.org/10.1016/J.MEASUREMENT.2022.112330

    Article  Google Scholar 

  50. de Martini Fernandes L et al (2019) Thermal model for surface grinding application. Int J Adv Manuf Technol 104(5–8):2783–2793. https://doi.org/10.1007/S00170-019-04101-6/FIGURES/16

    Article  Google Scholar 

  51. Vafaei S, Wen D, Borca-Tasciuc T (2011) Nanofluid surface wettability through asymptotic contact angle. Langmuir 27(6):2211–2218. https://doi.org/10.1021/LA104254A/ASSET/IMAGES/MEDIUM/LA-2010-04254A_0011.GIF

    Article  Google Scholar 

  52. Shokoohi Y, Shekarian E (2016) Application of nanofluids in machining processes - a review. J Nanosci Nanotechnol 2(1):59–63

  53. Sharma A, Tiwari A, Dixit A (2014) Progress of nanofluid application in machining: a review. Mater Manuf Process. https://doi.org/10.1080/10426914.2014.973583

  54. Setti D, Sinha MK, Ghosh S, Venkateswara Rao P (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. https://doi.org/10.1016/J.IJMACHTOOLS.2014.10.005

    Article  Google Scholar 

  55. da Silva LR, Bianchi EC, Fusse RY, Catai RE, França TV, Aguiar PR (2007) Analysis of surface integrity for minimum quantity lubricant—MQL in grinding. Int J Mach Tools Manuf 47(2):412–418. https://doi.org/10.1016/J.IJMACHTOOLS.2006.03.015

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Production Engineering Department, Alexandria University, Alexandria, 21544, Egypt

    Yassmin Seid Ahmed

  2. Study Center of CAD/CAM, Holguin University, 80100, Holguin, CP, Cuba

    Luis Wilfredo Hernández González

Authors
  1. Yassmin Seid Ahmed
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Luis Wilfredo Hernández González
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yassmin Seid Ahmed.

Ethics declarations

Ethical approval

Not pertinent.

Consent to participate

Everyone involved in the project gave their consent.

Consent for publication

This particular piece of writing has never been published before and is not currently being considered for publication elsewhere.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Seid Ahmed, Y., González, L.W.H. Ti6Al4V grinding using different lubrication modes for minimizing energy consumption. Int J Adv Manuf Technol 126, 2387–2405 (2023). https://doi.org/10.1007/s00170-023-11203-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11203-9

Keywords

Search

Navigation