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Minimum quantity lubrication machining nickel base alloy: a comprehensive review

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Abstract

Nickel-based alloys have great application value in aerospace, biomedical industry, chemical industry, and other fields. However, nickel-based alloys are known to be difficult to process, which will generate a lot of heat and friction during processing, which limits the application range of nickel-based alloys. Therefore, a large amount of cutting fluid needs to be used during processing, and the cutting fluid will cause harm to human health and the environment. In order to solve these problems, scholars proposed to use the minimum quantity lubrication (MQL) to replace the conventional flood cooling lubrication technique. Recently, many papers have proposed to use MQL for lubrication /cooling in the processing of nickel-based alloys. However, few studies have approached this topic comprehensively. To bridge this gap, this study conducts a comprehensive literature review of the progress made in the processing of nickel-based alloys using various MQL methods. It should be noted that these studies are divided into four categories: vegetable oil-based MQL, cryogenic cooling-based MQL, solid lubricant-based MQL, and electrostatic atomization-based MQL. It is crucial to compare the advantages of these cooling and lubricating technologies in machining nickel-based alloys, analyze their experimental results, and assess their impact on machining quality and tool wear. This review reveals that compared to traditional MQL, vegetable oil-based MQL is more energy-saving and environmentally friendly, resulting in approximately 30% improvement in surface quality and a 50% reduction in tool wear. The addition of solid lubricants to vegetable oil further enhances its lubrication performance. Cryogenic cooling-based MQL enables the attainment of finer grains and smaller sawtooth chips. Electrostatic atomization MQL, by altering the atomization process of traditional MQL, produces more uniform droplets, leading to a 42.4% reduction in tool wear and a 47% improvement in machined surface quality. The purpose of this paper is to help researchers identify existing gaps and to enable MQL to improve the processing quality and application range of nickel-based alloys. Finally, the present technical challenges and future research directions are put forward.

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Abbreviations

MQL:

Minimum quantity lubrication

Cryo-MQL, CMQL:

Cryogenic minimum quantity lubrication

EMQL, EL:

Electrostatic minimum quantity lubrication

Al2O3 :

Aluminum oxide

ZnO:

Zinc oxide

Gr:

Graphene

LN2 :

Liquid nitrogen

CO2 :

Liquid carbon dioxide

scCO2 :

Supercritical carbon dioxide

MWFs:

Metal working fluids

MoS2 :

Molybdenum disulfide

ZrO2 :

Zirconium dioxide

CNT:

Carbon nanotubes

PCD:

Polycrystalline diamond

SiO2 :

Silica dioxide

TOPSIS:

Technique for order preference by similarity to an ideal solution

CAPB:

Coco-amido-propyl-betaine

SDBS:

Sodium-dodecyl-benzenesulfonate

ANOVA:

Analysis of variance

CDA:

Composite desirability approach

AHP:

Analytical hierarchy process

SEM:

Scanning electron microscope

COPRAS:

Complex proportional assessment

scCO2 + OoW:

Supercritical carbon dioxide based minimum quantity lubrication with oil droplets cutting fluid

MRR:

Metal removal rate

RSM:

Response surface method

NMQL:

Nano-fluid minimum quantity lubrication

Ag:

Silver

Q:

Flow velocity

SDS:

Sodium dodecyl sulfate

TGRA:

Taguchi grey relational analysis

NP:

Nanoparticles

SiC:

Silicon carbide

WS2 :

Micron-scale tungsten disulfide

PVD:

Physical vapor deposition

MLG:

Multilayer graphene

CSI:

Conference on Surface Integrity

BUE:

Built up age

SCE:

Specific cutting energy

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Funding

This study was supported by a research project financed by the National Natural Science Foundation of China (number 5217052158).

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Authors and Affiliations

  1. Shanghai University of Engineering Science, Shanghai, 201620, China

    Shu Zhou, Dazhong Wang, Shujing Wu & Guquan Gu

  2. Harbin Institute of Technology, Harbin, 150001, China

    Guojun Dong

  3. Shanghai Jiao Tong University, Shanghai, 200240, China

    Qinglong An

  4. Changzhou Institute of Technology, Changzhou, 213032, China

    Hun Guo

  5. Qingdao University of Technology, Qingdao, 266520, China

    Changhe Li

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  1. Shu Zhou
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Conceptualization, Shu Zhou; software, Dazhong Wang and Shujing Wu; writing review, Guquan Gu and Guojun Dong; editing, Qinglong An, Hun Guo, and Changhe Li. All authors have read and agreed to the published version of the manuscript.

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Zhou, S., Wang, D., Wu, S. et al. Minimum quantity lubrication machining nickel base alloy: a comprehensive review. Int J Adv Manuf Technol 131, 2407–2445 (2024). https://doi.org/10.1007/s00170-023-11721-6

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