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Metal cutting, a complex process in manufacturing, involves various factors that significantly affect the quality of the final product. Notably, the turning process is crucial, with outcomes that heavily depend on multiple machining parameters. These parameters encompass speed, depth of cut, feed rate, the type of coolant used (specifically, high heat transfer MXene coolant), and insert types, among others. The material of the workpiece is also a critical factor in the metal-cutting operation. This study focuses on achieving optimal surface quality and minimizing cutting forces in the turning process. It recognizes the substantial impact of numerous process parameters, directly or indirectly affecting the product's surface roughness and cutting forces. Understanding these optimal parameters can lower machining costs and improve product quality. Our research concentrates on turning a stainless-steel alloy workpiece using a carbide insert tool. We employ the Response Surface Method (RSM) to optimize cutting parameters within a set range of cutting speed (100, 125, 150 m/min), feed rate (0.1, 0.2, 0.3 mm/rev), and depth of cut (0.4, 0.8, 1.2 mm). Additionally, we use various tool geometries and the RSM design of experiments to enhance and analyze the multi-response parameters of surface roughness and tool life. Optimal machining parameters for MXene-NFC involve a cutting speed of 140 m/min, a feed rate of 0.05 mm/rev, and a depth of cut of 0.5 mm. These settings ensure minimal surface roughness, maximum tool life, and the greatest total length of cut, achieving a composite desirability of 0.695. [ABSTRACT FROM AUTHOR]

The emphasis of this paper is to evaluate the thermophysical properties of crystalline nanocellulose (CNC)-based nanofluid and the optimized machining parameters (cutting speed, feed rate and depth of cut) for machining using CNC-based nanofluid. Cutting tool temperature and formed chip temperature during machining are determined with CNC-based coolant and metal working fluid. Minimum quantity lubrication technique is used to minimize the usage of the coolant. Nanocellulose coolant with a concentration of 0.5% shows better thermal conductivity and viscosity. Total heat produced at the cutting tool and the temperature generated at the chip during machining shows significant improvement using CNC-based nanofluid. Statistical analysis reveals that feed rate and depth of cut contribute around 27.48% and 22.66% toward cutting temperature. Meanwhile, none of the parameters significantly affects the heat transfer. The multi-objective optimization reveals that the optimum parameter for machining using CNC-based nanocoolant is: cutting speed = 120, feed rate = 0.05 and depth of cut = 1.78 which produces heat transfer of 379.44 J and cutting temperature of 104.41 °C. [ABSTRACT FROM AUTHOR]

Green cooling system usage in machining is getting favors to minimize the environmental effect such as pollutions. Around 20% of the machining cost is about coolant usage in flooded cooling technique. Even though coolant has a reasonably low cost, their handling and disposing cost are very high and also, threatening toxic contents, disposal of used coolant is a big problem as it can lead to hazardous effect to the machining operates as well as to the environment. As an alternative, a cooling technique known as minimum quantity lubrication (MQL) was introduced in the machining operation. For MQL technique, the coolant should exhibit superior properties which are effective in machining operation when compared with the conventional machining coolant which is metal working fluid (MWF). Owing to the technology advancements by nanotechnology in nanomaterial, the nanofluid is a promising coolant that can replace the conventional machining coolant. In the present work, ethylene glycol/nanocellulose-based nanofluid is evaluated in terms of its thermo-physical properties and its effectiveness in machining performances which is temperature distribution in cutting tool and compare its effectiveness with MWF. Its effectiveness is tested in turning machining operation of SUS 304 stainless steel using cemented tungsten-cobalt (WC-Co)-coated carbide cutting insert. The turning operation by using ethylene glycol/nanocellulose-based nanofluid coolant with 0.5 vol% which exhibit a superior thermal conductivity of 0.449 W/m K than 0.267 W/m K thermal conductivity of MWF at 30 °C. The recorded lower amount of heat transfer to the cutting tool is 863 J compared with 1130 J when using MWF. On the other hand, the maximum temperature reading recorded at chip formed by using MWF is 225 °C whereas by using nanofluid is 154 °C which promises lower temperature distribution to chip formed during the machining operation. Also, the functionality of nanofluid as a thermal transport during machining is proven via chip formation observation analysis and scanning electron microscope (SEM) with energy-dispersive X-ray (EDX) spectrum analysis. [ABSTRACT FROM AUTHOR]

This paper discuss the tool life and wear mechanism in the end-milling of AISI304 stainless steel using a TiN-coated carbide insert with water-soluble coolant and nanoparticle-based coolant (TiO/EG). The cutting variables are cutting speed, feed rate, and axial depth. The end-milling operation using nanoparticle-based coolant (TiO/EG) obtains a high tool life compared with the end-milling operation using water-soluble coolant. In general, the tool failure when milling with water-soluble coolant was flank wear, cracking, chipping, and fracture at a cutting distance of 720 mm, but the milling process with nanoparticle-based coolant (TiO/EG) showed chipping and fracture at a cutting distance of 1200 mm. According to ISO 8688-2-1989 (E), the wear criterion for milling with water-soluble coolant is reached at an average cutting distance of 800 mm, but milling with nanoparticle-based coolant (TiO/EG) reached the ISO 8688-2-1989 (E) wear criterion at a cutting distance of 1300 mm. The SEM and EDX spectra show that there are nanolayers of Ti nanoparticles from the nanofluid embedded in and filling the holes in the insert, forming a layer which acts as a thermal bridge for the cutting insert. Attrition and oxidation at the cutting edge were the main tool wear mechanisms present during the end-milling operation with nanoparticle-based coolant (TiO/EG). An oxide layer formed during the oxidation wear which shielded the cutting tool from impact during the milling process. [ABSTRACT FROM AUTHOR]

A promising alternative to conventional fluid coolant application is minimum quantity lubrication (MQL). Despite much research, there have been few investigations about the influence of MQL parameters on the process results, such as oil flow rate, workpiece speed and depth of cut. The objective of this project is to develop a mathematical model of the material removal rate and surface roughness on grinding of ductile cast iron using minimum quantity lubrication. The experiment was carried out according to the design of experiment principle, prepared based on central composite design. The experimental data was utilized to develop the mathematical model for first- and second-order models. The second order gives acceptable performance of the grinding. The result shows that the highest value of the grinding ratio is with single-pass MQL, and the lowest value is with multiple-pass conventional coolants. The model fit was adequate and acceptable for sustainable grinding using a 0.15% volume concentration of ethylene glycol. This paper quantifies the impact of water-based ethylene glycol on the surface quality achieved. It is concluded that the surface quality is most influenced by the depth of cut and table speed. It is recommended that future research is also conducted using another parameter such as the speed of the grinding wheel or the distance from the wheel-workpiece contact zone. Besides that, further research can be conducted using different nozzle angles and different types of grinding wheel to see how these affect the surface of the material. [ABSTRACT FROM AUTHOR]

This paper presents the effects of various milling conditions on the tool wear and workpiece temperature when using ethylene-glycol-based TiO2 nanofluid as the coolant for stainless steel AISI 304. A TiN coated carbide insert is used as the milling tool. A thermocouple was embedded into the workpiece to record the workpiece temperature during the end-milling process. It can be clearly seen that the temperature keeps on increasing after each experimental pass for three sets of experiments. The experiment conducted using the ethylene-glycol-based TiO2 nanocoolant exhibits a much lower workpiece temperature compared to the experiment conducted using a normal commercial coolant. Milling with the ethylene-glycol-based TiO2 nanocoolant reduced the wear on the edge of the insert compared to the normal commercial coolant. In conclusion, end-milling stainless steel AISI 304 using a TiN coated carbide insert and an ethylene-glycol-based TiO2 nanocoolant exhibits superior results with regard to workpiece temperature and tool wear. The temperature was reduced by 30 percent when using the nanofluid [ABSTRACT FROM AUTHOR]

Due to the increasing demand in industrial application, nanofluids have attracted the considerable attention of researchers in recent decades. The addition of nanocellulose (CNC) with water (W) and ethylene glycol (EG) to a coolant for a radiator application exhibits beneficial properties to improve the efficiency of the radiator. The focus of the present work was to investigate the performance of mono or hybrid metal oxide such as Al2O3 and TiO2 with or without plant base-extracted CNC with varying concentrations as a better heat transfer nanofluid in comparison to distilled water as a radiator coolant. The CNC is dispersed in the base fluid of EG and W with a 60:40 ratio. The highest absorption peak was noticed at 0.9% volume concentration of TiO2, Al2O3, CNC, Al2O3/TiO2, and Al2O3/CNC nanofluids which indicates a better stability of the nanofluids' suspension. Better thermal conductivity improvement was observed for the Al2O3 nanofluids in all mono nanofluids followed by the CNC and TiO2 nanofluids, respectively. The thermal conductivity of the Al2O3/CNC hybrid nanofluids with 0.9% volume concentration was found to be superior than that of the Al2O3/TiO2 hybrid nanofluids. Al2O3/CNC hybrid nanofluid dominates over other mono and hybrid nanofluids in terms of viscosity at all volume concentrations. CNC nanofluids (all volume concentrations) exhibited the highest specific heat capacity than other mono nanofluids. Additionally, in both hybrid nanofluids, Al2O3/CNC showed the lowest specific heat capacity. The optimized volume concentration from the statistical analytical tool was found to be 0.5%. The experimental results show that the heat transfer coefficient, convective heat transfer, Reynolds number and the Nusselt number have a proportional relationship with the volumetric flow rate. Hybrid nanofluids exhibit better thermal conductivity than mono nanofluids. For instance, a better thermal conductivity improvement was shown by the mono Al2O3 nanofluids than the CNC and TiO2 nanofluids. On the other hand, superior thermal conductivity was observed for the Al2O3/CNC hybrid nanofluids compared to the other mono and hybrid ones (Al2O3/TiO2). [ABSTRACT FROM AUTHOR]

Highlights • Machining performances using ethylene glycol/nanocellulose based nanofluid. • 0.5 vol% EG/nanocellulose based MWF generates 1130 J of heat transfer at 30 °C. • Maximum temperature at chip formed by using nanofluid is 154 °C. Abstract In this paper, cellulose nanocrystal (CNC) – ethylene glycol (EG) + Water (W) based nanofluid was developed and assessed for their thermophysical properties and the usefulness towards machining performances. The nanofluid was prepared by adopting two-step preparation method and at volume concentration of 0.1%, 0.3%, 0.5%, 0.7%, 0.9%, 1.1%, 1.3% and 1.5%. The nanofluid with 1.3% and 1.5% concentration showed to have superior the conductivity properties, around 0.559 W/m·K at 70 °C. However, the 0.5% concentration has the highest stability with 0.52 W/m·K at 70 °C. The 0.5% nanofluid concentration was then selected for the machining performance evaluation. The machining performance was evaluated by using a lathe machining operation to determine the heat transfer and tool life properties. The cutting variables such as cutting speed, depth of cut and feed rate are varied to understand the effect of developed nanofluid on the machining bahaviour. Findings revealed that the tool failure on machining using MWF is flank wear, chipping and abrasion and fractured at the maximum cutting distance of 500 mm. However, machining using CNC-EG+W nanofluid revealed the tool failure to be flank wear, adhesion and build- up-edge (BUE) and fractured at the maximum cutting distance of 772 mm. [ABSTRACT FROM AUTHOR]