Investigation of sustainable machining of TI-6AL-4V using graphene enhanced minimum quantity lubrication

Abstract

The aerospace, biomedical engineering, and military industries have recently relied on titanium alloys due to their exceptional strength to weight ratio and corrosion resistance. However, titanium alloys are known to be challenging to machine due to their low thermal conductivity, high hardness, and tendency to chemically react with all tool materials at high temperatures. To overcome this issue, the use of cutting fluid has an important role in reducing the high temperature and friction that occurs in machining processes. However, excessive or incorrect use of cutting fluids has adverse effects on human health and the environment. Therefore, The Minimum Quantity Lubrication (MQL) technique has gained significant interest in machining processes to reduce the environmental impact caused using traditional cutting fluids. Recently, nanofluids have become increasingly utilized in the mechanical engineering field due to their superior lubrication and heat dissipation capabilities. The objective of this study is to enhance the surface roughness using cutting fluid with added nanoparticles during the turning process of Ti-6Al-4V alloy. Several factors such as chip formation, tool degradation, and surface characteristics were examined at varying cutting speeds, feed rates, cutting conditions, and nanoparticle concentrations.

Keywords

• Minimum Quantity Lubrication
• Sustainable Machining
• Ti-6AL-4V

References

1. References
2. [1] Yücel, A., et al. “Influence of MoS₂ Based Nanofluid-MQL on Tribological and Machining Characteristics in Turning of AA 2024 T3 Aluminum Alloy.” Journal of Materials Research and Technology, vol. 15, 2021, pp. 1688–1704.
3. [2] Li, N., Chen, Y.-J., and Kong, D.-D. “Multi-Response Optimization of Ti-6Al-4V Turning Operations Using Taguchi-Based Grey Relational Analysis Coupled with Kernel Principal Component Analysis.” Advances in Manufacturing, vol. 7, no. 2, 2019, pp. 142–154.
4. [3] Singh, R., et al. “Optimization of Machining Parameters Under MQL Turning of Ti-6Al-4V Alloy with Textured Tool Using Multi-Attribute Decision-Making Methods.” World Journal of Engineering, 2019.
5. [4] Gaurav, G., et al. “Assessment of Jojoba as a Pure and Nano-Fluid Base Oil in Minimum Quantity Lubrication (MQL) Hard-Turning of Ti–6Al–4V: A Step Towards Sustainable Machining.” Journal of Cleaner Production, vol. 272, 2020, p. 122553.
6. [5] Boswell, B., et al. “A Review Identifying the Effectiveness of Minimum Quantity Lubrication (MQL) During Conventional Machining.” The International Journal of Advanced Manufacturing Technology, vol. 92, no. 1, 2017, pp. 321–340.
7. [6] Ramanathan, A., et al. “Development of a Low Cost Eco-Friendly Minimum Quantity Lubrication System for Machining Processes.” Journal of Modern Mechanical Engineering and Technology, vol. 8, 2021, pp. 37–47.
8. [7] Tesma411. [Online]. Available: https://www.ijeast.com/papers/263-266,IJEAST.pdf.

9. [8] Yin, Q., et al. “Effects of Physicochemical Properties of Different Base Oils on Friction Coefficient and Surface Roughness in MQL Milling AISI 1045.” International Journal of Precision Engineering and Manufacturing-Green Technology, vol. 8, no. 6, 2021, pp. 1629–1647.
10. [9] Sharmin, I., et al. “Preparation and Evaluation of a Stable CNT-Water Based Nano Cutting Fluid for Machining Hard-to-Cut Material.” SN Applied Sciences, vol. 2, no. 4, 2020, pp. 1–18.
11. [10] Khandekar, S., et al. “Nano-Cutting Fluid for Enhancement of Metal Cutting Performance.” Materials and Manufacturing Processes, vol. 27, no. 9, 2012, pp. 963–967.
12. [11] Li, Y., Zhou, J., Tung, S., Schneider, E., and Xi, S. “A Review on Development of Nanofluid Preparation and Characterization.” Powder Technology, vol. 196, 2009, pp. 89–101. doi: 10.1016/j.powtec.2009.07.025.
13. [12] Srikant, R., Krishna, V., Syed, I., and Paliwal, U. “Development of Finite Element Based Model for Performance Evaluation of Nano Cutting Fluids in Minimum Quantity Lubrication.” CIRP Journal of Manufacturing Science and Technology, vol. 21, 2018, pp. 75–85. doi: 10.1016/j.cirpj.2018.02.005.
14. [13] Chakraborty, S., and Panigrahi, P.K. “Stability of Nanofluid: A Review.” Applied Thermal Engineering, vol. 174, 2020, p. 115259.
15. [14] Prasad, M.M.S., and Srikant, R.R. “Performance Evaluation of Nano Graphite Inclusion in Cutting Fluids with MQL Technique in Turning of AISI 1040 Steel.” International Journal of Research in Engineering and Technology, vol. 2, no. 11, 2013, pp. 381–393.
16. [15] Rahmati, B., Sarhan, A.A.D., and Sayuti, M. “Morphology of Surface Generated by End Milling AL6061-T6 Using Molybdenum Disulfide (MoS₂) Nanolubrication in End Milling Machining.” Journal of Cleaner Production, vol. 66, 2013, pp. 685–691. doi: 10.1016/j.jclepro.2013.10.048.
17. [16] Jamil, M., Khan, A.M., Hegab, H., Gong, L., Mia, M., Gupta, M.K., et al. “Effects of Hybrid Al₂O₃-CNT Nanofluids and Cryogenic Cooling on Machining of Ti-6Al-4V.” International Journal of Advanced Manufacturing Technology, vol. 102, no. 9–12, 2019, pp. 3895–3909.
18. [17] Thakur, A., Manna, A., and Sushant, S. “Multi-response Optimization of Turning Parameters During Machining of EN-24 Steel with SiC Nanofluids Based Minimum Quantity Lubrication.” Silicon, vol. 12, 2020, pp. 71–85.
19. [18] Li, B., Li, C., Zhang, Y., Wang, Y., Jia, D., Yang, M., et al. “Heat Transfer Performance of MQL Grinding with Different Nanofluids for Ni-Based Alloys Using Vegetable Oil.” Journal of Cleaner Production, vol. 154, 2017, pp. 1–11.
20. [19] Jamil, M., et al. “Effects of Hybrid Al₂O₃-CNT Nanofluids and Cryogenic Cooling on Machining of Ti–6Al–4V.” The International Journal of Advanced Manufacturing Technology, vol. 102, no. 9, 2019, pp. 3895–3909.
21. [20] Kalita, P., Malshe, A.P., Kumar, S.A., and Yoganath, V.G. “Study of Specific Energy and Friction Coefficient in Minimum Quantity Lubrication Grinding Using Oil-Based Nanolubricants.” Journal of Manufacturing Processes, vol. 18, 2012, pp. 1–9.
22. [21] Sinha, M.K., Ghosh, R.M.S., and Rao, P.V. “Application of Eco-Friendly Nanofluids During Grinding of Inconel 718 Through Small Quantity Lubrication.” Journal of Cleaner Production, vol. 141, 2017, pp. 1359–1375.
23. [22] Nam, J.S., Lee, P.H., and Lee, S.W. “Experimental Characterization of Micro-Drilling Process Using Nanofluid Minimum Quantity Lubrication.” International Journal of Machine Tools and Manufacture, vol. 51, 2011, pp. 649– 652.
24. [23] Hegab, H., Kishawy, H. A., Gadallah, M. H., Umer, U., & Deiab, I. “On Machining of Ti-6Al-4V Using Multi-Walled Carbon Nanotubes-Based Nano-Fluid Under Minimum Quantity Lubrication.” The International Journal of Advanced Manufacturing Technology, vol. 97, no. 5, 2018, pp. 1593–1603.
25. [24] Gupta, M. K., Sood, P. K., & Sharma, V. S. “Optimization of Machining Parameters and Cutting Fluids During Nano-Fluid Based Minimum Quantity Lubrication Turning of Titanium Alloy by Using Evolutionary Techniques.” Journal of Cleaner Production, vol. 135, 2016, pp. 1276–1288.
26. [25] Singh, R., Dureja, J. S., Dogra, M., Gupta, M. K., Mia, M., & Song, Q. “Wear Behavior of Textured Tools Under Graphene-Assisted Minimum Quantity Lubrication System in Machining Ti-6Al-4V Alloy.” Tribology International, vol. 145, 2020, p. 106183.
27. [26] Shuang, Y., John, M., & Songlin, D. “Experimental Investigation on the Performance and Mechanism of Graphene Oxide Nanofluids in Turning Ti-6Al-4V.” Journal of Manufacturing Processes, vol. 43, 2019, pp. 164–174.
28. [27] Eltaggaz, A., Nouzil, I., & Deiab, I. “Machining Ti-6Al-4V Alloy Using Nano-Cutting Fluids: Investigation and Analysis.” Journal of Manufacturing and Materials Processing, vol. 5, no. 2, 2021, p. 42.
29. [28] Sodavadia, K. P., & Makwana, A. H. “Experimental Investigation on the Performance of Coconut Oil Based Nano Fluid as Lubricants During Turning of AISI 304 Austenitic Stainless Steel.” International Journal of Advanced Mechanical Engineering, vol. 4, no. 1, 2014, pp. 55–60.
30. [29] Gaurav, G., Sharma, A., Dangayach, G. S., & Meena, M. L. “Assessment of Jojoba as a Pure and Nano-Fluid Base Oil in Minimum Quantity Lubrication (MQL) Hard-Turning of Ti–6Al–4V: A Step Towards Sustainable Machining.” Journal of Cleaner Production, vol. 272, 2020, p. 122553.
31. [30] Yi, S., Li, G., Ding, S., & Mo, J. “Performance and Mechanisms of Graphene Oxide Suspended Cutting Fluid in the Drilling of Titanium Alloy Ti-6Al-4V.” Journal of Manufacturing Processes, vol. 29, 2017, pp. 182–193.
32. [31] Songmei, Y., Xuebo, H., Guangyuan, Z., & Amin, M. “A Novel Approach of Applying Copper Nanoparticles in Minimum Quantity Lubrication for Milling of Ti-6Al-4V.” Advances in Production Engineering & Management, vol. 12, no. 2, 2017.
33. [32] Singh, V., Sharma, A. K., Sahu, R. K., & Katiyar, J. K. “Novel Application of Graphite-Talc Hybrid Nanoparticle Enriched Cutting Fluid in Turning Operation.” Journal of Manufacturing Processes, vol. 62, 2021, pp. 378–387.
34. [33] Kumar, S. P., & Prasada, H. T. “Investigate the Effect of Nano Cutting Fluid and Cutting Parameters Under Minimum Quantity Lubrication (MQL) on Surface Roughness in Turning of DSS-2205.” Materials Today: Proceedings, vol. 43, 2021, pp. 3643–3649.
35. [34] Yıldırım, Ç. V., Şirin, Ş., & Kivak, T. “Waspaloy Süper Alaşımının Frezelenmesinde Nanopartikül Katkılı Yağlamanın Takım Aşınması Üzerindeki Etkisinin Araştırılması.” Düzce Üniversitesi Bilim ve Teknoloji Dergisi, vol. 7, no. 1, 2019, pp. 466–476.
36. [35] Gupta, M. K., Jamil, M., Wang, X., Song, Q., Liu, Z., Mia, M., … & Imran, G. S. “Performance Evaluation of Vegetable Oil-Based Nano-Cutting Fluids in Environmentally Friendly Machining of Inconel-800 Alloy.” Materials, vol. 12, no. 17, 2019, p. 2792.
37. [36] Yıldırım, Ç. V. “Grafit Parçacık Takviyeli Nano Akışkan Kullanılarak AISI 316’nın Frezelenmesinde Yüzey Pürüzlülüğü ve Kesme Sıcaklığının Optimizasyonu.” Düzce Üniversitesi Bilim ve Teknoloji Dergisi, vol. 7, no. 1, 2019, pp. 326–341.
38. [37] Ibrahim, A. M. M., Li, W., Zeng, Z., Bedairi, B. H., & ElSheikh, A. “Graphene Nanoplatelets–Water Nanofluids: A Sustainable Approach to Enhancing Ti‑6Al‑4V Grinding Performance Under Minimum Quantity Lubrication Conditions.” Tribology International, vol. 201, 2025, p. 110145.
39. [38] Singh, R., Dureja, J. S., Dogra, M., Gupta, M. K., & Mia, M. “Influence of Graphene-Enriched Nanofluids and Textured Tools on the Machining Behavior of Ti‑6Al‑4V Alloy.” The International Journal of Advanced Manufacturing Technology, vol. 105, 2019, pp. 1685–1697.
40. [39] Lisowicz, J., Habrat, W., Krupa, K., Mrówka-Nowotnik, G., Szroeder, P., Zawada-Michałowska, M., & Korpysa, J. “The Use of Graphite Micropowder in the Finish Turning of the Ti‑6Al‑4V Titanium Alloy Under Minimum Quantity Lubrication Conditions.” Materials, vol. 17, no. 24, 2024, p. 6121.
41. [40] Duc, T. M., Long, T. T., & Tuan, N. M. “Performance Investigation of MQL Parameters Using Nano Cutting Fluids in Hard Milling.” Fluids, vol. 6, no. 7, 2021, p. 248.
42. [41] Abdelkrem, E., Ali, S., Badwal, K., & Deiab, I. “Influence of Nanoparticle Concentration in Nanofluid MQL on Cutting Forces, Tool Wear, and Chip Morphology During Milling of Inconel 718.” The International Journal of Advanced Manufacturing Technology, vol. 129, 2023, pp. 1787–1800.
43. [42] Kara, F. “Investigation of the Effect of Al₂O₃ Nanoparticle-Added MQL Lubricant on Sustainable and Clean Manufacturing.” Lubricants, vol. 12, no. 11, 2024, p. 393.
44. [43] Dalke, P. A., Karanjkar, A. V., & Deshmukh, G. P. “A Review: Nanofluids in Machining for Performance and Sustainability.” Journal of Physics: Conference Series, vol. 2763, 2024, p. 012012.
45. [44] Bastas, A. “Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes.” Sustainability, vol. 13, no. 8, 2021, p. 4271.
46. [45] Kumar, A., Sharma, A. K., & Katiyar, J. K. “State-of-the-Art in Sustainable Machining of Different Materials Using Nano Minimum Quantity Lubrication (NMQL).” Lubricants, vol. 11, no. 2, 2023, p. 64.