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A comprehensive review on minimum quantity lubrication (MQL) in machining processes using nano-cutting fluids

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Abstract

The cutting fluid is significant in any metal cutting operation, for cooling the cutting tool and the surface of the workpiece, by lubricating the tool-workpiece interface and removing chips from the cutting zone. Recently, many researchers have been focusing on minimum quantity lubrication (MQL) among the numerous methods existing on the application of the coolant as it reduces the usage of coolant by spurting a mixture of compressed air and cutting fluid in an improved way instead of flood cooling. The MQL method has been demonstrated to be appropriate as it fulfills the necessities of ‘green’ machining. In the current study, firstly, various lubrication methods were introduced which are used in machining processes, and then, basic machining processes used in manufacturing industries such as grinding, milling, turning, and drilling have been discussed. The comprehensive review of various nanofluids (NFs) used as lubricants by different researchers for machining process is presented. Furthermore, some cases of utilizing NFs in machining operations have been reported briefly in a table. Based on the studies, it can be concluded that utilizing NFs as coolant and lubricant lead to lower tool temperature, tool wear, higher surface quality, and less environmental dangers. However, the high cost of nanoparticles, need for devices, clustering, and sediment are still challenges for the NF applications in metalworking operations. At last, the article identifies the opportunities for using NFs as lubricants in the future. It should be stated that this work offers a clear guideline for utilizing MQL and MQL-nanofluid approaches in machining processes. This guideline shows the physical, tribological, and heat transfer mechanisms associated with employing such cooling/lubrication approaches and their effects on different machining quality characteristics such as tool wear, surface integrity, and cutting forces.

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Abbreviations

MQL:

Minimum quantity lubrication

LN2 :

Liquid nitrogen

NDM:

Near-dry machining

MQC:

Minimum quantity cooling

PVD:

Physical vapor deposition

DLC:

Diamond-like carbon

HBUE:

Built-up-edge

MWCNTs:

Multi-walled carbon nanotubes

Al2O3 :

Aluminum oxide

CuO:

Copper (II) oxide

pH:

Scale of acidity

BFO:

Bacterial foraging optimization

PSO:

Particle swarm optimization

SQCL:

Small quantity cooling lubrication

SDBS:

Sodium dodecylbenzene sulfonate

SLS:

Sodium lauryl sulfate

TiO2 :

Titanium dioxide

MoS2 :

Molybdenum disulfide

NFMQL:

Nanofluid-minimum quantity lubrication.

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Funding

The University of Sharjah, Projects #18020406118, provided financial support.

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Authors and Affiliations

  1. Sustainable Energy Development Research Group, College of Engineering, University of Sharjah, Sharjah, United Arab Emirates

    Zafar Said

  2. Department of Mechanical Engineering, Guru Jambheshwar University of Science & Technology, Hisar, India

    Munish Gupta & Neeti Arora

  3. Mechanical Design and Production Engineering Department, Cairo University, Giza, Egypt

    Hussien Hegab

  4. Department of Mechanical Manufacture and Automation, Nanjing University of Aeronautics & Astronautics, Nanjing, China

    Aqib Mashood Khan & Muhammad Jamil

  5. Thermal Department, School of Mechanical Engineering, National Technical University of Athens, Athens, Greece

    Evangelos Bellos

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  1. Zafar Said
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  2. Munish Gupta
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  3. Hussien Hegab
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  5. Aqib Mashood Khan
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Correspondence to Zafar Said.

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Said, Z., Gupta, M., Hegab, H. et al. A comprehensive review on minimum quantity lubrication (MQL) in machining processes using nano-cutting fluids. Int J Adv Manuf Technol 105, 2057–2086 (2019). https://doi.org/10.1007/s00170-019-04382-x

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