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• The lubrication performance studies on the blended coolant were carried out with difficult-to-process materials. • This study gives the optimum blended coolant concentration according to different processing conditions. • The effects of different lubricating conditions on surface quality and tool wear were discussed. • The improved TOPSIS algorithm was applied for determining the preferable blended coolant concentration. Minimal quantity lubrication (MQL) has often been adopted to improve the machinability of difficult-to-process materials such as Ti-6Al-4 V. High disposal costs, toxicity, and environmental pollution generally prevent the further application of traditional coolants. Hence, this study aimed to determine the best ratio of castor oil (CO) and ethanol (E) in a new eco-friendly vegetable oil-based coolant fluid, along with the best combination of cutting parameters. The performance of the coolant fluid was evaluated by measuring the surface roughness and flank wear under three different lubricating conditions (dry machining, flood machining, and CO-E blended coolant-based MQL conditions). Under the blended coolant-based MQL conditions, the surface roughness was reduced by 36% and 15% compared with that of dry machining and flood machining, respectively, and the tool wear was reduced by 38% and 53%, respectively. The best parameter combinations are a blended coolant ratio R CO/E = 31% / 69%, cutting velocity v c = 100 m/min, feed f = 0.075 mm, and depth of cut a p = 0.2 mm. This eco-friendly blended coolant fluid can boost the heat exchange capacity and lubrication performance, thereby improving the processing characteristics. [ABSTRACT FROM AUTHOR]

Carbon fiber-reinforced composites (CFRP), known for its impressive specific strength and modulus, finds extensive applications in defense, aerospace, automotive, and various other industries. Nevertheless, the widespread application of dry cutting in machining Carbon Fiber Reinforced Polymer (CFRP) presents significant challenges, including dust pollution, fiber layer delamination, and uneven surface quality. These issues make the machining of CFRP a formidable task. In the present investigation, a novel nanohybrid cutting fluid was successfully prepared by adding molybdenum disulfide (MoS 2)/silicon carbide (SiC) nanoparticles to a base-cutting fluid synthesize from ethanol, polyethylene glycol, and sodium dodecyl sulfate. Moreover, employing minimal lubrication techniques, the nano-cutting fluid was applied to the milling process of CFRP. The feasibility of applying the cutting fluid to CFRP machining was demonstrated through short beam shear tests. Horizontal comparative milling tests were executed on CFRP, varying operational parameters and cooling-lubrication scenarios. The cooling-lubrication mechanisms of the nanofluid were analyzed, providing further validation of the effectiveness of the cutting fluid in CFRP machining. The results suggest that the nanofluid has a negligible impact on the interlaminar shear strength of CFRP, with only a 3.85% reduction. In comparison to other cooling-lubrication conditions, milling CFRP with the novel nanofluid resulted in a reduction of milling forces by 4.78%–24.84%, a decrease in milling temperatures by 15.38%–69.37%, a lowering of surface roughness by 10.78%–35.93%, and a reduction in tool tip wear by 6.25%–53.81%. Observable phenomena such as fiber pull-out and fracture were significantly reduced. • A nanohybrid cutting fluid suitable for CFRP machining is prepared, which is free of precipitation, agglomeration and delamination. • The effect of nano-cutting fluid on the mechanical properties of CFRP was proved to be negligible by interlayer shear strength tests. • The experimental results of cutting force, cutting temperature, surface quality and tool wear in milling CFRP were analyzed through comparative tests, which proved that the prepared nano-cutting fluid has good cooling and lubricating properties. • This study focuses on the development of a nano-cutting fluid tailored for CFRP. The findings contribute valuable insights into the selection of cutting fluids for CFRP machining. [ABSTRACT FROM AUTHOR]

Based on the principle of different technical components, this study divides the research field of minimum quantity lubrication (MQL) technology (synergism technology, vegetable oil-based cutting fluid, oil mist control, MQL system, and process optimization) and comprehensively analyzes the relevant literature in different research fields. The contents include a review and summary of the characteristics of each field, an analysis of the advantages and development challenges in each field, and a description of the future development trends of MQL in each field. The analyses mentioned above are performed from the perspective of the promotion of sustainable processing and cleaner production. The objective is to achieve better cooling and lubrication effects, and reduce the adverse effects on the environment. The study also provides new research concepts for the future development of MQL technology. • The development of MQL in different manufacturing processes are summarized, from 2000 to 2021. • Some technical challenges of MQL (oil mist pollution control, intelligent system development, etc) are discussed. • The development trend of MQL technology in the future is pointed out. [ABSTRACT FROM AUTHOR]