Studies on dry wet and Magnetorheological fluid based Minimum quantity lubrication for Machining of monel k500 alloy

Abstract

Smart cutting tools have potential benefits in manufacturing technologies with innovative design concepts like Force sensitive smart cutting tool, thermo-sensitive internal cooled cutting tool, and advanced Minimum Quantity Lubrication system (MQL). Innovative perspectives on machining hard alloys using smart cutting tools have been a major demand over a variety of industrial applications. Among various techniques of smart assistance, the MQL technique posses a remarkable reduction in machining costs. It also creates an excellence in machinability characteristics with a drastic reduction of cutting tool temperature, chip thickening ratio and wear. The fluid film formed with the MQL process on the rake face of the tool chip interference maintains the hydrophilic nature of the lubricant in maintaining the contact angle nearer to the absolute wetting angle which is one of the difficulties faced in commercial cutting fluids/biolubricant. Nano additives such as Al2O3, TiO2, MoS2, CuO, graphene, CNT(carbon nano tubes), MWCNT (Multi Walled Carbon Nano Tubes), ZrO2, WS2, B2O3, CaF2, Hbn, PTFE (Polytetrafluoroethylene), ZnO, Ag, Cu, WO3, and Fe3O4 improve the tribological, wettablity, surface deposition, lubrication, thermal conditions, flowability, and machining characteristics. In the use of the variant MQL system, the main disadvantage is that it couldn t retain the fluid with its surface tension over the tool substrate for a longer time with the same surface tension and wetting angle. The viscous nature of the fluid cannot be controlled prominently with induced cutting force. Hence there is a need for a smart fluid assisted MQL system that should retain the rheological properties with adaptive controlling in viscous nature to promote the flow of nano additives in the lubricant. newline