Skip to main content
SpringerLink
Log in

Spectral analysis and power spectral density evaluation in Al2O3 nanofluid minimum quantity lubrication milling of 45 steel

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

Abstract

Nanofluid minimum quantity lubrication (NMQL) is one of the main modes of sustainable manufacturing. It is an environment-friendly, energy-saving, and highly efficient lubrication method. With the use of nanoparticles, the tribological properties of debris–tool and workpiece–tool interfaces will change. However, spectrum analyses of force and power spectral density (PSD) of surface microstructures are limited. In the present work, the milling force, friction coefficient, specific energy, surface roughness, and surface microstructure of debris were evaluated in milling of 45 steel for different lubrication conditions, namely, dry, flood, minimum quantity lubrication, and Al2O3 NMQL. Results demonstrated that compared with other lubrication conditions, NMQL achieves minimum milling force peak (Fx = 270 N, Fy = 160 N, Fz = 50 N), friction coefficient (μ = 1.039), specific energy (U = 65.5 J/mm3), and surface roughness value (Ra = 2.254 μm, RSm = 0.0562 mm). Furthermore, a spectrum analysis of the milling force and PSD of the surface microstructure was conducted for validation. The spectral analysis of milling force revealed that NMQL obtained the lowest milling force and amplitude in the middle-frequency region, thereby indicating the minimum abrasion loss of the tool. Meanwhile, the PSD analysis indicated that NMQL had the lowest proportional coefficient in the low-frequency region (0.4766) and the highest proportional coefficient in the high-frequency region (0.0569). These results revealed that the workpiece surface gained by Al2O3 NMQL obtained higher wave fineness than other working conditions. By combining with the lowest Ra, NMQL contributes the best workpiece surface quality. Therefore, machining experiments using NMQL showed the best lubrication performance.

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

References

  1. Li CH, Hou YL, Xiu SC, Cai GQ (2008) Application of lubrication theory to near-dry-green grinding-feasibility analysis. Adv Mater Res 44-46:135–142

    Article  Google Scholar 

  2. Zhang YB, Li CH, Jia DZ, Zhang DK, Zhang XW (2015) Experimental evaluation of the lubrication performance of MoS2/CNT nanofluid for minimal quantity lubrication in Ni-based alloy grinding. Int J Mach Tools Manuf 99:19–33

    Article  Google Scholar 

  3. Zhang YB, Li CH, Jia DZ, Zhang DK, Zhang XW (2015) Experimental evaluation of MoS2 nanoparticles in jet MQL grinding with different types of vegetable oil as base oil. J Clean Prod 871:930–940

    Article  Google Scholar 

  4. Ding WF, Zhang LC, Li Z, Zhu YJ, Su HH, Xu JH (2017) Review on grinding-induced residual stresses in metallic materials. Int J Adv Manuf Technol 88:2939–2968

    Article  Google Scholar 

  5. Ding WF, Barbara L, Zhu YJ, Li Z, Fu YC, Su HH, Xu JH (2017) Review on monolayer CBN superabrasive wheels for grinding metallic materials. Chin J Aeronaut 30:109–134

    Article  Google Scholar 

  6. Xi XX, Ding WF, Li Z, Xu JH (2017) High speed grinding of particulate reinforced titanium matrix composites using a monolayer brazed cubic boron nitride wheel. Int J Adv Manuf Technol 90:1529–1538

    Article  Google Scholar 

  7. Li Z, Ding WF, Liu CJ, Su HH (2017) Prediction of grinding temperature of PTMCs based on the varied coefficients of friction in conventional-speed and high-speed surface grinding. Int J Adv Manuf Technol 90:2335–2344

    Article  Google Scholar 

  8. Mao C, Tang XJ, Zou HF, Huang XM, Zhou ZX (2012) Investigation of grinding characteristic using nanofluid minimum quantity lubrication. Int J Precis Eng Man 13:1745–1752

    Article  Google Scholar 

  9. Wang YG, Li CH, Zhang YB, Yang M, Li BK, Jia DZ, Hou YL, Mao C (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

    Article  Google Scholar 

  10. Zhang XP, Li CH, Zhang YB, Wang YG, Li BK, Yang M, Guo SM, Liu GT, Zhang NQ (2016) 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

    Article  Google Scholar 

  11. Wang YG, Li CH, Zhang YB, Li BK, Yang M, Zhang XP, Guo SM, Liu GT (2016) Experimental evaluation of the lubrication properties of the wheel/workpiece interface in MQL grinding with different nanofluids. Tribol Int 99:198–210

    Article  Google Scholar 

  12. Zhang YB, Li CH, Ji HJ, Yang XH, Yang M, Jia DZ, Zhang XP, Li RZ, Wang J (2017) Analysis of grinding mechanics and improved predictive force model based on material-removal and plastic-stacking mechanisms. Int J Mach Tools Manuf 122:81–97

    Article  Google Scholar 

  13. Li CH, Li JY, Wang S, Jia DZ (2013) Modeling and numerical simulation of the grinding temperature distribution with nano-particle jet of MQL. Adv in Mech Eng 7:167–181

    Google Scholar 

  14. Li BK, Li CH, Zhang YB, Wang YG, Jia DZ, Yang M, Zhang NQ, Wu QD, Han ZG, Sun K (2017) Heat transfer performance of MQL grinding with different nanofluids for Ni-based alloys using vegetable oil. J Clean Prod 154:1–11

    Article  Google Scholar 

  15. Yang M, Li CH, Zhang YB, Jia DZ, Zhang XP, Hou YL, Li RZ, Wang J (2017) Maximum undeformed equivalent chip thickness for ductile-brittle transition of zirconia ceramics under different lubrication conditions. Int J Mach Tools Manuf 122:55–65

    Article  Google Scholar 

  16. Han ZL, Li CH (2010) The application of cutting fluid in grinding process is reviewed. Abras Abras Commun 10:7–12

    Google Scholar 

  17. Zhang DK, Li CH, Zhang YB, Zhou DZ (2015) Zhang XW. Experimental research on the energy ratio coefficient and specific grinding energy in nanoparticle jet MQL grinding. Int J Adv Manuf Technol 78:1275–1288

    Article  Google Scholar 

  18. Lv HG (2012) Tool wear of H13 steel hard milling process and its effect on the surface integrity. Shan Dong University 11-77

  19. Liao YS, Lin HM (2007) Mechanism of minimum quantity lubrication in high-speed milling of hardened steel. Int J Mach Tools Manuf 47:1660–1666

    Article  Google Scholar 

  20. Liao YS, Lin HM, Chen YC (2007) Feasibility study of the minimum quantity lubrication in high-speed end milling of NAK80 hardened steel by coated carbide tool. Int J Mach Tools Manuf 47:1667–1676

    Article  Google Scholar 

  21. Lacalle LNLD, Lamikiz A, Sánchez JA, Cabanes I (2001) Cutting conditions and tool optimization in the high-speed milling of aluminium alloys. Proc Inst Mech Eng B J Eng Manuf 215:1257–1269

    Article  Google Scholar 

  22. Shahrom MS, Yahya NM, Yusoff AR (2013) Taguchi method approach on effect of lubrication condition on surface roughness in milling operation. Procedia Eng 53:594–599

    Article  Google Scholar 

  23. Kishawy HA, Dumitrescu M, Ng EG, Elbestawi MA (2005) Effect of coolant strategy on tool performance, chip morphology and surface quality during high-speed machining of A356 aluminum alloy. Int J Mach Tools Manuf 45:219–227

    Article  Google Scholar 

  24. Sultan AA, Okafor AC (2016) Effects of geometric parameters of wavy-edge bull-nose helical end-mill on cutting force prediction in end-milling of Inconel 718 under MQL cooling strategy. J Manuf Process 23:102–114

    Article  Google Scholar 

  25. Rahmati B, Sarhan AAD, Sayuti M (2014) Morphology of surface generated by end milling AL6061-T6 using molybdenum disulfide (MoS2) nanolubrication in end milling machining. J Clean Prod 66:685–691

    Article  Google Scholar 

  26. Sharma AK, Tiwari AK, Dixit AR (2016) Effects of minimum quantity lubrication (MQL) in machining processes using conventional and nanofluid based cutting fluids: a comprehensive review. J Clean Prod 127:1–18

    Article  Google Scholar 

  27. Hadi M, Atefi R (2015) Effect of minimum quantity lubrication with gamma-Al2O3 nanoparticles on surface roughness in milling AISI D3 steel. Ind J Sci Technol 8:296–300

    Article  Google Scholar 

  28. Saravanakumar N, Prabu L, Karthik M, Rajamanickam A (2014) Experimental analysis on cutting fluid dispersed with silver nano particles. J Mech Sci Technol 28:645–651

    Article  Google Scholar 

  29. Uysal A, Demiren F, Altan E (2015) Applying minimum quantity lubrication (MQL) method on milling of martensitic stainless steel by using nano MoS2 reinforced vegetable cutting fluid. Procedia Soc Behav Sci 195:2742–2747

    Article  Google Scholar 

  30. Rahmati B, Sarhan AAD, Sayuti M (2014) Investigating the optimum molybdenum disulfide (MoS2) nanolubrication parameters in CNC milling of AL6061-T6 alloy. Int J Adv Manuf Technol 70:1143–1155

    Article  Google Scholar 

  31. Ming EO, Sayuti M, Sarhan AAD (2015) Fuzzy logic-based approach to investigate the novel uses of nano suspended lubrication in precise machining of aerospace AL tempered grade 6061. J Clean Prod 89:286–295

    Article  Google Scholar 

  32. Mao C, Zou HF, Huang XM, Zhang JA, Zhou ZX (2013) The influence of spraying parameters on grinding performance for nanofluids minimum quantity lubrication. Int J Adv Manuf Technol 64:1791–1799

    Article  Google Scholar 

  33. Okada M, Hosokawa A, Asakawa N, Ueda T (2014) End milling of stainless steel and titanium alloy in an oil mist environment. Int J Adv Manuf Technol 74:1255–1266

    Article  Google Scholar 

  34. Yuan SM, Yan LT, Liu WD, Liu Q (2011) Effects of cooling air temperature on cryogenic machining of Ti-6Al-4V alloy. J Mater Process Technol 211:356–362

    Article  Google Scholar 

  35. Su Y, Gong L, Li B, Liu Z, Chen D (2016) Performance evaluation of nanofluid mql with vegetable-based oil and ester oil as base fluids in turning. Int J Adv Manuf Technol 83:2083–2089

    Article  Google Scholar 

  36. Boswell B, Islam MN, Davies IJ, Ginting YR, Ong AK (2017) A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining. Int J Adv Manuf Technol 92:321–340

    Article  Google Scholar 

  37. Wang YG, Li CH, Zhang YB, Li BK, Yang M, Zhang XP, Guo SM, Liu GT, Zhai MG (2017) Comparative evaluation of the lubricating properties of vegetable-oil-based nanofluids between frictional test and grinding experiment. J Manuf Process 26:94–104

    Article  Google Scholar 

  38. Zhang YB, Li CH, Jia DZ, Li BK, Wang YG, Yang M, Hou YL, Zhang XW (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

    Article  Google Scholar 

  39. Feng J (2009) Study on Mechanism of Ti6Al4V high speed machining under different cooling lubrication conditions. Shan Dong University 35–38

  40. Oliveira GDP, Fonseca MC, Araujo AC (2017) Analysis of residual stress and cutting force in end milling of Inconel 718 using conventional flood cooling and minimum quantity lubrication. Int J Adv Manuf Technol 92:3265–3272

    Article  Google Scholar 

  41. Pathania A, Singh S, Gupta D, Jain V (2015) Development and analysis of tribological behavior of microwave processed EWAC+20% WC10Co2Ni composite cladding on mild steel substrate. J Manuf Process 20:79–87

    Article  Google Scholar 

  42. Guo SM, Li CH, Zhang YB, Wang YG, Li BK, Yang M, Zhang XP, Liu GT (2016) 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 140:1060–1076

    Article  Google Scholar 

  43. Mittal RK, Kulkarni SS, Singh RK (2017) Effect of lubrication on machining response and dynamic instability in high-speed micromilling of Ti-6Al-4V. J Manuf Process 28:413–421

    Article  Google Scholar 

  44. Štefánia Olejárová DJ, Svetlík J, Pituk M (2017) Measurements and evaluation of measurements of vibrations in steel milling process. Measurement 106:18–25

    Article  Google Scholar 

  45. Liu C, Wu JQ, Li GH, Tan GY (2013) Frequency-spectrum characteristics of force in end milling with tool wear and eccentricity. Int J Adv Manuf Technol 67:925–938

    Article  Google Scholar 

  46. Kang IS, Kim JH, Hong C, Kim JS (2010) Development and evaluation of tool dynamometer for measuring high frequency cutting forces in micro milling. Int J Precis Eng Manuf 11:817–821

    Article  Google Scholar 

  47. Liu P, Xu JH, Fu YC (2011) Cutting force and its frequency spectrum characteristics in high speed milling of titanium alloy with a polycrystalline diamond tool. J ZheJiang Univ 12:56–62

    Article  Google Scholar 

  48. Nikoo MF, Azizi H, Parvin N, Naghibi HY (2016) The influence of heat treatment on microstructure and wear properties of friction stir welded AA6061-T6/Al2O3, nanocomposite joint at four different traveling speed. J Manuf Process 22:90–98

    Article  Google Scholar 

  49. Mia M, Bashir MA, Khan MA, Dhar NR (2017) Optimization of MQL flow rate for minimum cutting force and surface roughness in end milling of hardened steel (HRC 40). Int J Adv Manuf Technol 89:675–690

    Article  Google Scholar 

  50. Wang Z, Kovvuri V, Araujo A, Bacci M, Hung WNP, Bukkapatnam STS (2016) Built-up-edge effects on surface deterioration in micromilling processes. J Manuf Process 24:321–327

    Article  Google Scholar 

  51. Ho JK, Che HT, Ming YT, Ming XT, Sung JC (2015) Development of a novel cooling system-assisted minimum quantity lubrication method for improvement of milling performance. J Chin Inst Eng 38:322–331

    Article  Google Scholar 

Download references

Funding

This research was financially supported by the National Natural Science Foundation of China (51575290), Major Research Project of Shandong Province (2017GGX30135), Shandong Provincial Natural Science Foundation, China (ZR2017PEE002 and ZR2017PEE011), and Scientific Research Development Project of Shandong Higher Education Institutions, China (J17KB016).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Qingdao University of Technology, Qingdao, 266520, China

    Qingan Yin, Changhe Li, Yanbin Zhang, Min Yang, Dongzhou Jia & Yali Hou

  2. Department of Biomedical Engineering, University of Southern California, Los Angeles, CA, 90089-1111, USA

    Runze Li

  3. School of Mechanical and Electrical Engineering, Qingdao Binhai University, Qingdao, 266555, China

    Lan Dong

Authors
  1. Qingan Yin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Changhe Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yanbin Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Min Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Dongzhou Jia
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Yali Hou
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Runze Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Lan Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Changhe Li.

Additional information

1. Milling performance of 45 steel under different lubricating conditions was studied.

2. The tribological properties of Al2O3 nanofluid in milling were studied.

3. Spectrum analysis of milling force was conducted.

4. Power spectral density of surface microstructure was performed to validation.

5. The best lubrication performance was proved to be NMQL.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yin, Q., Li, C., Zhang, Y. et al. Spectral analysis and power spectral density evaluation in Al2O3 nanofluid minimum quantity lubrication milling of 45 steel. Int J Adv Manuf Technol 97, 129–145 (2018). https://doi.org/10.1007/s00170-018-1942-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-1942-9

Keywords

Search

Navigation