Performance evaluation of MQL with AL2O3 mixed nanofluids prepared at different concentrations in milling of Hastelloy C276 alloy

Abstract

Since some deficiencies in mist lubri-cooling techniques i.e., minimum quantity lubrication (MQL) in heavy cutting conditions have been noticed, recently nano-cutting fluids which have enrich thermal conductivity than base fluid, are begun to be used in MQL system. One of the critical issues arising in this process is the addition of the appropriate nanoparticle ratio to the base liquid. Therefore, this study aimed to find the optimum distribution rate of Al2O3 nanoparticles having excellent properties and machining parameters. For this purpose, by adding Al2O3 nanoparticles to vegetable-based cutting fluid, nano-cutting fluids were prepared in different volumetric concentrations (0.5, 1.0 and 1.5 vol%). These prepared nanofluids were used in the MQL system when milling of Hastelloy C276. Three cutting speeds (60, 75 and 90 m/min) and three different feed rates (0.10, 0.15 and 0.20 mm/rev) were added to the experimental design to study the performance of nanofluids under several cutting parameters. Apart from this experimental design, to clearly see the effect of concentration rates on tool wear and tool life, three experiments were carried out at each concentration ratio by keeping the machining parameters. Eventually, 1 vol% Al2O3 concentration clearly provided an improvement by up to 23% and 10% in tool life, compared to 0.5 vol% and 1.5 vol% concentration, respectively. In addition, while chipping/fracture, attrition wear and peeling of coating were observed under all cutting conditions, there was no evidence for workpiece material adhesion at 1 vol% and 1.5 vol% Al2O3 based nanofluid-MQL.

Keywords

• Hastelloy C276
• Al2O3 based nano-cutting fluid
• Tool wear
• Wear mechanisms
• Surface roughness