A review on sustainable machining: Technological advancements, health and safety considerations, and related environmental impacts

Ammar Elsheikh; Ali B.M. Ali; Amal Saba; Hosam Faqeha; Albraa A. Alsaati; Abdullah M. Maghfuri; Walaa Abd-Elaziem; Ahmed A. El Ashmawy; Ninshu Ma

Results in Engineering (Dec 2024)

A review on sustainable machining: Technological advancements, health and safety considerations, and related environmental impacts

Ammar Elsheikh,
Ali B.M. Ali,
Amal Saba,
Hosam Faqeha,
Albraa A. Alsaati,
Abdullah M. Maghfuri,
Walaa Abd-Elaziem,
Ahmed A. El Ashmawy,
Ninshu Ma

Affiliations

Ammar Elsheikh: Department of Production Engineering and Mechanical Design, Faculty of Engineering, Tanta University, Tanta, 31527, Egypt; Corresponding author. Department of Production Engineering and Mechanical Design, Faculty of Engineering, Tanta University, Tanta, 31527, Egypt.
Ali B.M. Ali: Department of Production Engineering and Mechanical Design, Faculty of Engineering, Tanta University, Tanta, 31527, Egypt; Faculty of Engineering, Pharos University in Alexandria, Egypt; Department of Histology, Faculty of Medicine, Tanta University, Tanta, 31527, Egypt; Mechanical Engineering Department, Umm Al-Qura University, Makkah, 21955, Saudi Arabia; Department of Mechanical Design and Production Engineering, Faculty of Engineering, Zagazig University, P.O. Box 44519, Egypt; Department of Materials Science and Engineering, Northwestern University, Evanston, IL, 60208, USA; Air Conditioning Engineering Department, College of Engineering, University of Warith Al-Anbiyaa, Karbala , Iraq; National Institute of Oceanography and Fisheries, Cairo, Egypt; Department of Mechanical Engineering, College of Engineering and Computer Sciences, Jazan University, Jazan,45142, Saudi Arabia; Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaragi, Osaka, 567-0047, Japan
Amal Saba: Department of Histology, Faculty of Medicine, Tanta University, Tanta, 31527, Egypt
Hosam Faqeha: Mechanical Engineering Department, Umm Al-Qura University, Makkah, 21955, Saudi Arabia
Albraa A. Alsaati: Mechanical Engineering Department, Umm Al-Qura University, Makkah, 21955, Saudi Arabia
Abdullah M. Maghfuri: Department of Production Engineering and Mechanical Design, Faculty of Engineering, Tanta University, Tanta, 31527, Egypt; Faculty of Engineering, Pharos University in Alexandria, Egypt; Department of Histology, Faculty of Medicine, Tanta University, Tanta, 31527, Egypt; Mechanical Engineering Department, Umm Al-Qura University, Makkah, 21955, Saudi Arabia; Department of Mechanical Design and Production Engineering, Faculty of Engineering, Zagazig University, P.O. Box 44519, Egypt; Department of Materials Science and Engineering, Northwestern University, Evanston, IL, 60208, USA; Air Conditioning Engineering Department, College of Engineering, University of Warith Al-Anbiyaa, Karbala , Iraq; National Institute of Oceanography and Fisheries, Cairo, Egypt; Department of Mechanical Engineering, College of Engineering and Computer Sciences, Jazan University, Jazan,45142, Saudi Arabia; Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaragi, Osaka, 567-0047, Japan
Walaa Abd-Elaziem: Department of Materials Science and Engineering, Northwestern University, Evanston, IL, 60208, USA
Ahmed A. El Ashmawy: Department of Production Engineering and Mechanical Design, Faculty of Engineering, Tanta University, Tanta, 31527, Egypt; Faculty of Engineering, Pharos University in Alexandria, Egypt; Department of Histology, Faculty of Medicine, Tanta University, Tanta, 31527, Egypt; Mechanical Engineering Department, Umm Al-Qura University, Makkah, 21955, Saudi Arabia; Department of Mechanical Design and Production Engineering, Faculty of Engineering, Zagazig University, P.O. Box 44519, Egypt; Department of Materials Science and Engineering, Northwestern University, Evanston, IL, 60208, USA; Air Conditioning Engineering Department, College of Engineering, University of Warith Al-Anbiyaa, Karbala , Iraq; National Institute of Oceanography and Fisheries, Cairo, Egypt; Department of Mechanical Engineering, College of Engineering and Computer Sciences, Jazan University, Jazan,45142, Saudi Arabia; Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaragi, Osaka, 567-0047, Japan
Ninshu Ma: Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaragi, Osaka, 567-0047, Japan

Journal volume & issue: Vol. 24
p. 103042

Abstract

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The evolution of advanced engineering materials and high-speed cutting techniques has emphasized the critical role of cutting fluids (CFs) in machining processes to meet sustainability requirements. Cutting fluids application offers several key benefits, including temperature reduction during cutting, decreased friction between the workpiece/chip and tool, extended tool lifespan, enhanced machining efficiency, and boosted surface finish. These positive outcomes are primarily attributed to the core functions of cutting fluid, namely lubrication, cooling, cleaning, and corrosion protection. However, they have serious disadvantages such as posing risks to ecosystems and human health as well as high disposal costs. Despite these disadvantages, ongoing research and development efforts are focused on improving the environmental sustainability, health and safety, and performance of metal cutting fluids through the use of green biodegradable oils, developing advanced recycling technologies, and the use of efficient application methods such as high-pressure cooling and minimum quantity lubrication (MQL). This review paper sheds light on sustainable machining technologies that are utilized to minimize the environmental impacts of conventional cutting fluids. Different types of CFs including their benefits and role in cutting operations are also introduced. Finally, sustainable assessment including economical, environmental, and social aspects of green machining technologies is discussed.

Published in Results in Engineering

ISSN: 2590-1230 (Online)
Publisher: Elsevier
Country of publisher: Netherlands
LCC subjects: Technology
Website: https://www.journals.elsevier.com/results-in-engineering

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