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Performance assessment of reinforced nanofluid with surface-active agent for machinability improvement

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Abstract

The machining industry’s current trend is to increase machinability attributes and process performance so that nanofluid can be the right choice for the achievement. Two critical factors are evaluated to improve machining efficiency, including cooling-lubrication parameters and cutting fluid types. Therefore, in the present work, the main focus is on reinforcing the cutting fluid (nanofluid) and its injection technique to obtain optimal conditions. The results showed that since the nanoparticles had a high area-to-volume ratio, by passing time, their adherence inclination to each other was enhanced and immense pile was created. Therefore, it was swiftly deposited and a low volume nanofluid was produced. In other words, the single-phase nanofluid became into a two-phase fluid and two regions including nanoparticles and low volume nanofluid was attained. This event led to decline the nanoparticles transmitted through the cutting fluid that caused to decrease surface integrity and intensify tool wear. This phenomenon thoroughly confirmed by scanning electron microscope images and energy-dispersive X-ray spectroscopy analysis. Hence, surface-active agent (surfactant) were added to the nanofluid as a new additive, which resulted in significant stability in the nanoparticles’ buoyancy. Surface roughness and cutting force experiments indicated that the surfactant significantly reduced the removed regions on the workpiece surface and improved the surface roughness by 13% and 34% and cutting force by 14% and 2% compared with non-surfactant nanofluid and conventional cutting fluid. This improvement reached its maximum through the green technique of minimum quantity lubrication (MQL), which led to a more detailed study of MQL parameters and the optimal conditions in the present work. According to the experiments, the optimal surface quality, tool wear, and cutting force values were achieved at the flow rate, injection pressure, and tool-nozzle gap of 300 ml/h, 6 bar, and 3 cm.

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Data availability

The authors confirm that the data supporting the findings of this study are available within the article [and/or] its supplementary materials.

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Abbreviations

F.M:

Flood mode

EDX:

Energy-dispersive X-ray spectroscopy

C.F:

Conventional cutting fluid

N.F:

Nanofluid

N.F + S:

Nanofluid with surfactant

MQL:

Minimum quantity lubrication

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Funding

The research presented in this paper was funded by the Iran National Science Foundation: INSF, Iran National Elites Foundation, and Fundamental Research Funds for the Amirkabir University of Technology No.4014405.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Amirkabir University of Technology, Tehran, Iran

    Seyed Hasan Musavi & Mohammad Reza Razfar

  2. School of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran

    Seyed Hasan Musavi & Behnam Davoodi

Authors
  1. Seyed Hasan Musavi
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  2. Behnam Davoodi
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  3. Mohammad Reza Razfar
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Contributions

S.H. Musavi designed and performed experiments, analyzed data, and wrote the paper. B. Davoodi and M.R. Razfar supervised the research. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Seyed Hasan Musavi.

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Highlights

• The tests showed that the performance of the unreinforced nanofluid after a short time is very similar to the conventional cutting fluid, and the nanoparticles are practically useless.

• Nanofluid reinforced with surfactant from the sodium dodecyl sulfate (SDS) group showed an excellent performance from the viewpoint of tool wear and surface quality.

• Adhesion was the dominant tool wear mechanism in aluminum alloy machining, in which the two main products were the built-up edge and built-up layer.

• Although adhesion wear has a simple appearance and low risk, after a short machining time dramatically affects the tool’s strength. In addition, it leads to horrible breakage in the cutting tool.

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Musavi, S., Davoodi, B. & Razfar, M.R. Performance assessment of reinforced nanofluid with surface-active agent for machinability improvement. Int J Adv Manuf Technol 128, 3983–4001 (2023). https://doi.org/10.1007/s00170-023-12061-1

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