Abstract
Nanofluid minimum quantity lubrication (NMQL) is a resource-saving, environment-friendly, and efficient green processing technology. Cottonseed oil can form a strong lubricating film owing to its abundant saturated fatty acids and monounsaturated fatty acids, which have excellent lubricating properties. The physical and chemical properties of nanofluids change when Al2O3 nanoparticles are added. However, the effects of cottonseed oil–based Al2O3 nanofluid concentrations on the milling force and workpiece surface quality remain unclear. To address this limitation, 45 steel was used to conduct NMQL milling experiments of cottonseed oil–based Al2O3 nanofluids with different mass fractions. Results showed that the minimum milling force was obtained at a concentration of 0.2 wt% (Fx = 58 N, Fy = 12 N). The minimum surface roughness value (Ra = 1.009 μm, RSm = 0.136 mm) was obtained at a mass concentration of 0.5 wt%, and the micromorphology of the workpiece/chip was optimal.
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Abbreviations
- MQL:
-
Minimum quantity lubrication
- SEM:
-
Scanning electron microscope
- W s :
-
Rotation rate (r/min)
- V f :
-
Feed rate (mm/min)
- V :
-
Cutting speed
- a p :
-
Axial depth of cut (mm)
- a e :
-
Radial depth of cut (mm)
- α :
-
Angle of the nozzle and the cutter feeding direction
- β :
-
Angle of nozzle and horizontal direction
- γ :
-
Cut in angle
- Fx, Fy, Fz :
-
Cutting force component in the X, Y, and Z directions (N)
- NMQL:
-
Nanofluid minimum quantity lubrication
- \( {\overline{F}}_{\mathrm{max}} \) :
-
Mean of milling force peak (N)
- R a :
-
Arithmetic average height (μm)
- RS m :
-
Mean spacing at mean line (mm)
- R mr :
-
Bearing length ratio
- μ n :
-
Viscosity of the nanofluid
- μ bf :
-
Viscosity of the base fluid
- \( R{S}_m=\frac{1}{N}\sum \limits_{i=1}^n{S}_i \) :
-
Nanoparticle mass fraction
- γ sv :
-
Surface tension at the solid–gas interface
- γ sl :
-
Surface tension at the solid–liquid interface
- γ vl :
-
Surface tension at the gas–liquid interface
- θ :
-
Contact angle
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Funding
This research was financially supported by the following organizations: The National Natural Science Foundation of China (51575290 and 51806112), the Major Research Project of Shandong Province (2017GGX30135 and 2018GGX103044), and the Shandong Provincial Natural Science Foundation of China (ZR2017PEE002 and ZR2017PEE011).
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Highlights
• NMQL milling experiments of cottonseed oil–based Al2O3 nanofluids of different mass fractions (0 wt%, 0.2 wt%, 0.5 wt%, 1 wt%, 1.5 wt%, 2 wt%) were carried out with 45 steel.
• The lubrication properties of cottonseed oil–based Al2O3 nanofluids of different mass fractions milling 45 steel were compared.
• The surface morphology of workpiece and debris was analyzed.
• The lubricating mechanisms of cottonseed oil and antiwear and antifriction mechanism of Al2O3 nanoparticles as lubricant additives were analyzed.
• The optimum mass concentration of Al2O3 nanofluids (0.5 wt%) with cottonseed oil as the base oil was obtained.
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Duan, Z., Yin, Q., Li, C. et al. Milling force and surface morphology of 45 steel under different Al2O3 nanofluid concentrations. Int J Adv Manuf Technol 107, 1277–1296 (2020). https://doi.org/10.1007/s00170-020-04969-9
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DOI: https://doi.org/10.1007/s00170-020-04969-9