The document summarizes various cooling and lubrication techniques used in machining difficult-to-cut materials like titanium alloys and nickel alloys. It discusses dry machining, conventional cooling, high-pressure cooling and nano-minimum quantity lubrication (MQL) techniques. Experimental results show that dry machining leads to high tool wear due to heat accumulation. Conventional cooling provides some benefits but its effectiveness reduces at high speeds. High-pressure cooling helps reduce tool wear compared to other techniques but requires high energy. Nano-MQL mixing nanoparticles into cutting oil enhances thermal conductivity and lubrication, lowering tool wear.

1. State-of-the-art Cooling and Lubrication for machining
Presented by : Presented to:
Manufacturing engineering,
School of Mechanical sciences,
Indian Institute of Technology,
Bhubaneswar
Dr. Gaurav Bartarya
Dr. Chetan
Atul Kumar Yadav
21MF06004
Review Research Presentation on
1

2. CONTENTS
 Introduction
 Literature Review
 Experimental procedure and parameters
• Dry Machining of Ti-6246 titanium alloy
• Dry Machining of Inconel 718
• Conventional cooling system
• High-Pressure Cooling.
• Nano-MQL turning of nickel alloy
 Discussion
• Wear behavior and tool life.
• Comparison of C&L techniques
Conclusions
 References 2

3. Attempts to increase the amount or benefits of goods and
services to meet the needs of living things
INTRODUCTION
c
MACHINING
TURNING
MILLING
DRILLING
GRINDING
Bulk deformation
Additive Manufacturing
Powder
Metallurgy
Unconventional
Machining
Manufacturing Processes
Production
Machining
 Heat at the cutting edge.
 High cutting energy
 Chip adhesion on the newly machined
surface
 poor surface quality
 Temperature-dependent wear of the
cutting tool
3

4. Machinability
Dry
Cooling
Wet cooling
MQL
Cryogenic
Cooling
High-Pressure
cooling
Sustainability
Economic
sustainability
Environmental
sustainability
Social
sustainability
Cooling /Lubrication
methods
State-of-use of the cooling lubrication
 Removing chips from machining zone
 Cooling
 Lubrication
 Preventing welding between cutting tool,
workpiece material and chips
 Cost
 Environmental damage
 Problems experienced in the disposal
and recycling
Application
Challenges
Contd..
4

5.  Minimum environmental damage
 Energy consumption
 Carbon emissions(Horizon-2020 to cut 20% of
co2-emission)
 Machinability characteristics
 Tool wear
 Surface roughness
 Temperature
Goals to achieve sustainable manufacturing processes
Contd..
5

6. Cutting Conditions
Dry machining
Low tool life
Bad surface
finish
Very high
friction
Conventional flood
cooling
High cost
compare to dry
Bad for
environment
Chip recycling
difficult
Not suitable for
difficult to
machine metals
MQL
Oil sprayed
with
compressed air
Reduces friction
Low waste
High pressure
Cooling
Water-based
cutting fluid
fluids at high
pressure
Contd..
6

7. Literature Review
Author Experiments Results
Andrea De
Bartolomeis
et al. (2020)
Cooling and Lubrication for
Machining Inconel 718
 High cutting speeds lead to catastrophic wear of flank face and
chipping of flank edge, with a predominance of abrasive wear.
 High temperatures at the tool workpiece interface resulted in the
vaporization of water-based cutting fluid.
 Fume that is considered as a cancer-causing substance is formed due
to the usage of the cutting oil.
Dahu Ju et
al.(2013)
Tool wear characteristics in
machining of nickel-based
super alloys
 Thermal softening, Diffusion and Notching at greater depth of
cut are the three main factors for tool wear
Thakur et al.
(2016)
Investigated the various parameters
like Cutting Force, tool chip
contact length and chip thickness
while machining Inconel 718
 High speed turning of Inconel 718 with uncoated carbide tool K20,
within the cutting speed range of 45–55 m/min, the dominant wear
mechanisms are abrasive wear, chipping and plastic deformation..
A. Jawaid et al.
(2021)
Tool wear characteristics in
turning of titanium alloy Ti-
6246
 Dominant wear mechanisms of cemented WC±Co tools were
dissolution and diffusion and attrition.
 Maximum flank wear was the factor controlling the tool life with all
tested tools.
7

8. Literature Review
Author Experiments Results
Nageswaran
Tamil Alagan
et al. (2019)
Effects of high-pressure cooling
in the flank and rake faces of
WC tool on the tool wear
mechanism and process
conditions in turning of alloy
718
 At low cutting speed (45 m/min) with a maximum pressure on the
both rake (16 MPa) and flank (8 MPa) reduced the mean Vbmax.
 High cutting speed (90 m/min), with a rake pressure of 16 MPa,
mean VB max and VB area reduced by approx. 25 and 19% with a
flank pressure of 8 MPa compared to no flank cooling condition.
Zhang et al.
(2014)
MoS2 nanoparticles in jet MQL
grinding of steel
 High viscosity of nanofluids significantly reduced heat transfer
performance while enhancing lubrication performance.
 Excessive mass fraction will result in nanoparticle agglomeration
and will break the lubricating property.
Pal et al.
(2021)
Nano- MQL with Al2O3 in
drilling of AISI 321stainless
steel
 Lower Cutting temperature , enhance tool life and reduce drilling
forces.
 The lubricating property of the various nanofluids:-
Al2O3 > SiO2 > MoS2 > CNTs> ZrO2
8

9. EXPERIMENTATION
Dry machining
 Machining or Cutting without using any fluids neither for cooling nor for
lubricating.
 Eliminate the Economic and Environmental issues associated with cutting fluid.
 Over-heating,
 Surface damage
 Limited cutting speeds
 Productivity
Limitation with Hard
material
9

10. Contd..
Fig. 1 An overview of the causes, mechanisms, types and consequences of the tool wear in cutting of nickel-based super alloy[3]
10

11. Dry Machining of Ti-6246 titanium alloy
Contd..
Workpiece materials
Machine CNC Lathe
Speed (m /min) 60,75,100
Feed Rate (mm/rev) 0.25,0.35
Depth of Cut (mm) 2
Ti-6246 Ultimate tensile strength
(MPa)
Elongation(%) Modulus of
elasticity(106 MPa)
Hardness
HBS/10(mm/3000 kg)
Al:6; Sn:2;
Zr:4; Mo:6
1170 10 11.3 380-390
Machining Parameter
Fig. 2. Diagram of worn cutting tool, showing the principal locations and
types of wear[6]
Table 1. Composition of Ti-6246 titanium alloy[2]
Table 2. Cutting parameters [6]
11

12. Contd..
Fig. 3. Average flank wear of the
carbide tools.[2]
Fig. 4. Tool life versus cutting speed.[2]
12

13.  High cutting speeds lead to catastrophic wear of flank
face and chipping of flank edge, with a predominance of
abrasive wear
 Flank wear rate increase with increase in the cutting
speed.
 Shorter contact area at the chip tool interface was
observed at high cutting speeds.
 This caused a concentration of high temperature very
close to the cutting edge
Fig. 5. SEM micrographs showing the
flank, rake and nose wear[2]
Contd..
13

14. Contd..
Difficult to cut material
 High material strength at elevated temperatures.
 Strain hardening.
 Low thermal conductivity,
 Chemical affinity to the majority of tool
materials,
 Welding and adhesion tendency leading to
frequent built-up edge (BUE) formation,
 High machining forces and vibrations.
Dry Machining of Inconel 718
Element Ni Cr Cb Mo Ti Al Co Si Mn Cu C P Fe
Weight % 53.4 18.8 5.27 2.99 1.02 0.50 0.17 0.12 0.07 0.07 0.03 0.01 Bal
Machine CNC Lathe
Speed (m /min) 40-60
Feed Rate (mm/rev) 0.05-0.09
Depth of Cut (mm) 0.5
Table 3. Cutting parameters for facing operation of
Alloy 718.[6]
Table 3. Composition of Inconel 718 [6]
14

15. Contd..
Fig. 6. Variation of flank wear with
cutting speed and feed at a
constant depth of cut of 0.5 mm
[6]
Fig. 7. Variation of flank wear
with cutting time.[6]
Fig. 8. SEM images of flank face and rake face
at different cutting speed.[6] 15

16. Cutting speed
and feed
increases
Strain rate in the
shear zone to be
high
Higher
temperature at
the tool–chip
interface
Speed increases
Time for heat
dissipation
decreases
Temperature
rises
Contd..
Fig. 9. Influence of cutting speed and feed
on cutting temperature at a constant depth
of cut of 0.5 mm. [6]
16

17. Conventional cooling
system
 To flood the machining area and provided
lubrication, heat dissipation, chip flushing as
well as chemical protection.
 Cutting fluids, also known as metalworking
fluids.
 Less surface damage.
 lowered the tensile residual stress
Cutting Fluids
Neat Cutting Oils
Mineral Oils
Fatty Oils
Water-Soluble
Fluids
Emulsifiable
Oils
Synthetic
Fluids
Semisynthetic
Gases
Air, Cooled Air
Ar,He,CO2
17

18.  Positive effects of lubricant were negligible at high-speed due to its
low thermal conductivity.
 High temperatures at the tool workpiece interface resulted in the
vaporization of water-based cutting fluid.
 “Steam blanket” formation, which significantly hindered the
reachability.
 Conventional cutting fluids start boiling at about 350 °C.
 Lose their cooling ability due to the Leiden frost effect.
 Leiden frost effect with increases in surface roughness.
 Due to local high temperatures, which resulted in high-frequency
BUE occurrence and detachment.
 Vapor layer traces on the cutting tool appear as a “dark region”
Leiden frost
effect
Drop of liquid
held up by layer
of vapour
surface temperature is higher than
the coolant boiling point
Contd..
Fig 10 Leiden frost effect [5]
18

19.  HPC supplies conventional water-based
cutting fluids at high pressure
 Kinetic force developed through pressures up
to 360 MPa Potential to eliminate the
undesirable vapor blanked, but also acts as a
“Hydraulic wedge.”
 Developing the desirable C-shaped chips.
 Environmentally unfriendly process due to
the use of high amount cutting fluids as well
as high energy requirements.
High-Pressure Cooling
Fig 11 Four modes of high-pressure coolant
supply [7] 19

20. Parameter Value
Spiral cutting
length, SCL
90 m
Feed rate, fn 0.2 mm/rev
Depth of cut, ap 1 mm
Material removed,
MR
18 cm3
Cutting speed, vc 45, 90 m/min
Rake pressure, RP 8, 16 MPa
Flank pressure, FP 0, 4, 8 MPa
S.No vc
(m/min)
Rake pressure,
RP (MPa)
Flank
pressure,
FP(MPa)
VBmax ±SD
(mm)
VBarea ±SD
(mm2)
1 45 8 0 0.18 ± 0.01 0.43 ± 0.06
2 45 8 4 0.18 ± 0.01 0.40 ± 0.03
3 45 8 8 0.18 ± 0.02 0.46 ± 0.08
4 45 16 0 0.14 ± 0.04 0.40 ± 0.08
5 45 16 4 0.17 ± 0.04 0.41 ± 0.08
6 45 16 8 0.14 ± 0.04 0.38 ± 0.08
7 90 8 0 0.69 ± 0.05 1.48 ± 0.26
8 90 8 4 0.65 ± 0.11 1.42 ± 0.31
9 90 8 8 0.70 ± 0.08 1.39 ± 0.16
10 90 16 0 0.78 ± 0.04 1.45 ± 0.12
11 90 16 4 0.64 ± 0.12 1.25 ± 0.35
12 90 16 8 0.58 ± 0.07 1.17 ± 0.14
Table 5. Cutting parameters for facing
operation of Alloy 718.[7]
Table 6. Measurement results of maximum flank wear and flank wear area
with standard deviation.[7]
Contd..
20

21. Fig. 12. Comparison of measured flank wear area for different flank and
rake pressures at cutting speeds of (a) vc 45 m/min, and (b) vc 90 m/min.[7]
 Wear levels were not influenced
when no flank coolant was used
and when the flank pressure
was 4 MPa
 Flank pressure of 8 MPa, the
downward wear rate trend was
regained.
Contd..
21

22. Why
nanofluids
are used in
MQL?
To increase
thermal
conductivity
When cutting velocity increases, oils due to their low thermal
conductivity become incapable of controlling heat, and their
viscosity also decreases.
Nano-particles have high thermal conductivity.
When mixed with MQL, increases the thermal conductivity of
coolant.
To increase
lubricating
property
Spherical in shape.
Nano-particles act as a
roller bearing between two
surface.
Acts as a filling material in
the micro-cracks. Nano
particles gets sintered.
MQL
Fig 13: Behaviour of nano-particles
between two surfaces [7]
22

23.  Two-step mixing process.
 Nano-particles was added to mineral
cutting oil in certain proportion.
 Mineral cutting oil and nanoparticles were
initially mixed at 1000 rpm for 60 min.
 After that, it was mixed for 60 min at
1500 rpm with magnetic stirrer.
 Nano-additives are distributed
homogeneously in mineral based cutting
oil.
Fig:13 Mixing of nano-particles with base
liquid [9]
Preparation of nano-MQL
23

24. Coefficient of friction
Fig.14. Variation in
coefficient of friction [9]
Lower friction between the tool-chip and workpiece-tool interface
it reduces the coefficient of kinetic friction but also reduces the
shear work.
 It leads to good cooling effect.
Coefficient of friction, μ =Ft /Fn
Where Ft is the thrust force (N) and Fn is the normal force (N).
The lowest value of COF (μ1.5 wt% = 0.004) was obtained at 5th
hole under nanofluid MQL drilling condition with 1.5 wt% of
graphene.
The heat transfer of oil with solid particles is higher than that pure
base oil.
 The addition of solid particles in base oil improve the thermal
conductivity of base oil and enhance the lubricationeffect.
24

25. Wear
Large amount of work material
adherend
Insufficient strength of oil film
Chip get melted and built up
edge formation
Low heat
transfer
capacity
 Graphene nanoparticle can strengthen the potentiality
for the load-carrying, wear resisting and reducing the
contact between tool-workpeice to good cooling-
lubrication effects of the oil films.
 High percentage of
nano-lubricant
concentration
the oil-
In this
graphene
act as a
increases
viscosity.
situation,
particles
roller
contacting
between
surfaces
and reducing the
COF.
Fig:15 - SEM micrographs of drill wear from
the bottom and cutting edge[9]
25

26. Nano-MQL Turning of AISI 3120 AA 2024 T3 aluminum alloy
Process Parameters
• Cutting fluid: MQL and nano-MoS2
MQL(0.6 wt percentage)
• Workpiece: 30mm thick square plate.
• Air Supply Pressure: 8 bar
• Fluid flow rate: 100ml/hr
• Tool: Uncoated cemented carbide
insert
• Nozzle dia: 2mm; nozzle angle: 30˚
• Cutting speed:300,400,500 m/min
• Feed: 0.1,0.2,0.3 mm/rev
• Depth of cut: 1mm
• Nose radius: 0.4mm
Experimental Method
• The cooling conditions and cutting parameters
such as cutting speed and feed rate were varied.
• Surface roughness and maximum temperature are
evaluated.
Fig:16 Experimental setup [8]
26

27. • Al alloys are ductile.
• Workpiece adheres to the cutting tool when machining
Al alloys under dry cutting condition.
• Cutting tool loses its ideal geometry and therefore
surface quality decreases.
• For these reasons, the use of cutting fluids has become
important when machining Al alloys.
Nano-MQL can solve the
above problem and
improve the productivity
• Temperature gets reduced by 22.5 percent
• BUE formation has been significantly eliminated by
NFMQL.
• The special rolling action of nano-particles and
enhancement of properties of base oil is main cause
of reduction in BUE.
Fig.17 a SEM image of cutting tool after dry assisted cutting of AA 2024 T3 alloy at cutting
speed of 500 m/min and feed rate of 0.3 mm/rev. [9]
Fig.17 b SEM image of cutting tool after MQL assisted cutting
of AA 2024 T3 alloy at cutting speed of 500 m/min
and feed rate of 0.3 mm/rev. [9]
Results
27

28. Nano-MQL turning of nickel alloy using ceramic tools
• It was observed that after a certain percentage of
addition of nano-particles to base oil, the performance
decreases.
• Tool life decreases if excess of nano particle is used.
• This is because of increase in viscosity.
• The nano-particles acts as a barrier and breaks the oil
film
• Excess nano particles creates additional asperities
which starts acting as abrasives.
Fig:18. Surface roughness under
difeerent conditions [10]
28

29. Discussion
Wear behavior and tool life.
Cooling scenario Tool life Cutting speed Feed rate Axial DOC Edge MRR
Dry ∼250 sec 60 m/min 0.075 mm/rev 0.8 mm 60 mm3/s
Dry 29 min 20 m/min 0.1 mm/rev 1 mm 33.3 mm3/s
Dry 6.5 min 40 m/min 0.1 mm/rev 1 mm 66.7 mm3/s
Dry 3 min 45 m/min 0.1 mm/rev 1 mm 75 mm3/s
Flood 57 min 40 m/min 0.15 mm/rev 0.25 mm 25 mm3/s
Flood 22 min 80 m/min 0.15 mm/rev 0.25 mm 50 mm3/s
Flood 104 s 300 m/min 0.2 mm/rev 1 mm 1000 mm3/s
HPC 8 MPa 30 min 50 m/min 0.1 mm/rev 1.5 mm 125 mm3/s
HPC 8 MPa 12 min 75 m/min 0.1 mm/rev 1.5 mm 187.5 mm3/s
HPC at 20 MPa 129 s 300 m/min 0.2 mm/rev 1 mm 1000 mm3/s
MQL ∼250 s 60 m/min 0.075 mm/rev 0.8 mm 60 mm3/s
Table 7 Tool life based on turning parameters and cooling scenarios [1]
29

30. Qualitative Comparison of Cooling and Lubrication
Discussion
FLOOD
DRY HPC MQL
Lubrication Inferior Superior Superior
Cooling Inferior Superior Inferior
Tool life extension Inferior Superior Similar
Machining forces decrement Inferior Superior Similar
Energy consumption reduction Superior Inferior Superior
Running costs reduction Superior Inferior Superior
Productivity Inferior Superior Similar
Workpiece surface integrity Inferior Superior Similar
Residue on chips reduction Superior Similar Similar
Turning suitability Inferior Superior Similar
High-speed machining aptness Inferior Superior Similar
Environmentally friendliness Superior Inferior Superior
Safety—healthiness Superior Inferior Superior
Evaporation of dangerous particles Superior Similar Inferior
Chip breakability Inferior Superior Inferior
Table 8 Qualitative comparison of dry, MQL and HPC machining of Inconel 718 with conventional flood technique[1]
30

31. Discussion
Fig. 19 Radar chart describing the comparison between different C&L technologies
31

32. Conclusions
 Dry machining Inconel 718 led to abrasion, adhesion, and welding of chips.
 Lubrication has been shown to be an effective solution to control BUE and premature chipping
 HPC, a pressurized jet can effectively penetrate the friction area and prevent BUE formation
 MQL increased tool life by reducing chip adherence
 Nano-MQL is highly capable of reducing friction and improving the surface quality due to the rolling
property of nano-particles
 740% extension in tool life with HPC over conventional machining.
 With the increase in the nano-particle ratio in the coolant, a worsening in tool life and surface roughness is
appeared
 Excess nano particles creates additional asperities which starts acting as abrasives and further increases
the friction..
32

33. References
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Cooling and Lubrication for Machining Inconel 718, Journal of Manufacturing Science and
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Wretland. Effects of high-pressure cooling in the flank and rake faces of WC tool on the tool wear
mechanism and process conditions in turning of alloy 718, Wear; 2019; 102992; 434-435
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Inconel 718 with coated carbide cutting tools; International Journal of Machine Tools & Manufacture;
2004;44:1481-1491
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superalloy Inconel 718 during high speed turning, Materials and Design;2009; 30:1718-1725.
7. Nageswaran Tamil Alagan ,Rabinarayan Bag, Amlana Panda , Ashok Kumar Sahoo, Ramanuj Kumar,
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process conditions in turning of alloy 718 of Materials Today Proceedings, 26(2020) 3094-3099
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34. 8. Amrit Pal a, Sukhpal Singh Chatha b, Hazoor Singh Sidhu, Performance evaluation of the minimum
quantity lubrication with Al2O3- mixed vegetable-oil-based cutting fluid in drilling of AISI 321 stainless
steel, Journal of Manufacturing Processes, 66 (2021) 238–249.
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35. THANK YOU
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