Influence of Al2O3/MoS2 hybrid nanofluid MQL technique on cutting forces and surface roughness in hard turning using CBN inserts

Abstract

Improving hard machining efficiency is a growing concern in industrial production, but environmentally friendly characteristics are guaranteed. Nanofluid minimum quantity lubrication (NF MQL) has emerged as a promising solution to improve cooling and lubrication performance in the cutting zone. This paper utilizes Box-Behnken experimental design to identify the influences of Al2O3/MoS2 hybrid nanofluid MQL hard turning using CBN inserts on surface roughness and cutting forces. Mathematical models were employed to predict thrust cutting force, tangential cutting force, and surface roughness in hard turning under MQL conditions using Al2O3/MoS2 hybrid nanofluid. The study results reveal that the minimum thrust force (Fy) occurs at a nanoparticle concentration of 0.5%, air pressure of 5 bar, and flow rate of 236 l/min. In comparison, the tangential force (Fz) reaches its minimum at a nanoparticle concentration of 0.8%, air pressure of 5 bar, and airflow rate of 227 l/min. The minimum surface roughness was achieved with a nanoparticle concentration of 1%, air pressure of 4.7 bars, and airflow rate of 186 l/min. Additionally, based on the multi-objective optimization, an optimal parameter set of NC=1%, p=5 bar, and Q = 210 l/min was identified to bring out the minimal values of surface roughness (Ra) of 0.218 µm, thrust force (Fy) of 115.9 N, and tangential force (Fz) of 93.3 N.

Keywords

• mql
• surface roughness
• hard turning
• hybrid nanofluids
• cutting force
• lubricant
• cbn