Journal of Huazhong University of Science and Technology ISSN-1671-4512

Performance Evaluation of Soybean Based Nanofluid Under

MQL, Flood and Dry at Different Speed-Depth of cut
Combinations

*1
P. Nageswara Rao , 2Suresh Babu Valeru and 3K.N.S Suman
1
Associate Professor, Mechanical Engineering Department, VVIT, Guntur,
Andhra Pradesh, India.
2
Research Scholar, Mechanical Engineering Department, Andhra University,
Visakhapatnam, A.P, India.
3
Associate Professor, Department of Mechanical Engineering, Andhra University,
Visakhapatnam, A.P, India
1
vvitpnr@gmail.com, 2valerusureshbabu23@gmail.com, 3
sumankoka@yahoo.com

Abstract: Nanofluids with vegetable oils as base fluids are widely used under minimum
quantity lubrication (MQL) technique for sustainable machining. In this work deals with
experimental investigation on the role of MQL and its importance by nanofluid (soybean
oil with 0.5% of rGO nanoparticles). Performance evaluation is conducted by the
generated cutting temperature at 4mm away tip of tool, cutting forces, roughness of the
machined surface and chip formation in turning of AISI 304 steel at different speed-depth
of cut combinations by carbide insert was taken. From the identified results significant
reduction in cutting forces and surface roughness by MQL over Flood and dry machining
mainly through reduction in the temperature generation and favorable change in the
chip-tool and work-tool interaction. Finally obtained results revealed that the MQL
system with soybean oil based nanofluid can enable improve the machining performance
and the additional cost of designing and implementation of MQL system.

Key Words: Soybean oil based nanofluid, Minimum quantity lubrication, Machining performance, Turning,
Carbide Insert

1. INTRODUCTION

MQL is an effective, environmentally friendly solution which has been widely used in
the various machining processes (i.e. turning, drilling and milling). Therefore Phafat et al.
[1] investigated machining with MQL method is introduced. From the whereas results
MQL increased the quality of the surface finish [2-4], improved tool life, reduced tool
wear, decreased cutting temperature and decreased the cost of lubrication [5-11]. The
efficiency of MQL has already been confirmed in many studies and application of various
machining process. For sustainable machining with MQL mainly depends of on type of
lubricant which will decide the effectiveness of MQL. From 19th centaury onwards many
lubricants such as mineral oils, synthetic oils, fatty alcohols, etc. [7]. Even vegetable oil
has been used and proven to be effective in machining [6,7]. However, the majorly
influencing thermophysical properties in machining compared to commercial lubricants
vegetable oils have low for this reason Nageswara Rao.et.al [12] prepared soybean oil
based nanofluid with nearer optimized fluid properties [13].
The present work investigates the performance of soybean oil based nanofluid under
dry, flood and minimum quantity lubrication environments at constant feed, different
speeds-depth of cut combinations in terms of cutting forces, generated maximum
temperature, surface roughness and chip morphology.

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Journal of Huazhong University of Science and Technology ISSN-1671-4512

2. EXPERIMENTAL CONDITIONS
With the combination of MQL and nanofluid from various literatures considered as a
rigorous solution in achieving sustainable machining. Therefore experimental testing have
been carried out by turning of workpiece (AISI 304 steel) with 100 mm length on a lathe
by a standard carbide insert. For the measurement of temperature a hole of 1.6 mm
diameter is made through the insert holder nearer to the insert rake face it is diagonally 4
mm away from the tip of the tool. In this hole, one end of the K- type thermocouple probe
of 1.5 mm diameter is fitted the other is connected temperature digital display unit. The
hole was made through the electro discharge machine.
For the performance evaluation of prepared oil tests have been carried with the
following conditions, which are shown in Table 1. All these parameters selected as based
on Lathe specifications for machining of AISI 304 steel with carbide insert.

Table 1. Experimental conditions.

Machine tool : Lathe Machine

Work materials : AISI 304 Steel
Cutting tool : Carbide Insert
Cutting parameters
Speed : 270, 421, 646 and 1000 rpm
Feed : 0.066 mm/rev
Depth of cut : 0.1,0.2 and 0.3 mm

The experimental set-up under different lubrications environments photographic views

is shown in Figure 1(a)-(c). A cylindrical bar of AISI 304 steel of 30 mm diameter was
selected for straight turning. The cutting insert is fixed with thermocouple sensor at 4 mm
away of the tip, during machining the generated maximum temperature is recorded by
thermocouple sensor and using lathe tool dynamometer cutting forces were recorded.
After conducting experiments the machined specimen’s surface roughness was measured
by a Talysurf using a sampling length of 4 mm and finally the chip morphology studies
were carried out under all constant conditions at different fluid environments.

(a) Dry (b) Flood (c) MQL

Figure 1. Machining with different coolant environments:

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3. RESULTS AND DISCUSSIONS

To observe the performance of soybean oil based nanofluid under different lubrication
conditions the obtained results discussed in following sections.

3.1 Cutting temperature

Machining with high speed and depth of cut inherently generate more amount of heat
as well as high cutting zone temperature. The magnitude of this cutting temperature
increases, though in different degree, with the increase of speed and depth of cut, as a
result, production levels is constrained by rise in temperature. In the present work
maximum temperature generated during machining at 4mm away of tool tip was
measured under dry, Flood and MQL with the help of thermocouple sensor.
The evaluated maximum temperature from 4mm away of tool tip in turning AISI 304
steel by carbide insert at different constant feed at different depth of cuts and speeds
combinations under both dry, flood and MQL condition and thermocouple setup shown in
Figure 2.

Figure 2. Thermocouple sensor with tool

In this research work, a tool-work thermocouple with proper calibration was used to
determine the maximum generated temperature at 4 mm away of tool tip during turning of
AISI 304 steel at various cutting speeds and depth of cuts. The obtain results were plotted
against different cutting speeds under dry, flood and MQL condition shown in Figure
3(a)-(c).

Depth of cut 0.1mm Depth of cut 0.2mm

150 150
Temperature (0C)
Temperature (0C)

Dry Dry
100 100
Flood
Flood
50 50 MQL
MQL

0 0
270 421 646 1000 270 421 646 1000
Speed(rpm) Speed(rpm)

(a) (b)

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Depth of cut 0.3mm

Temperature (0C)
150 Dry
100 Flood

50 MQL

0
270 421 646 1000
Speed(rpm)

(c)

Figure 3. Generated maximum temperature (0C) from 4 mm away of tool tip vs

Speeds (rpm) under different Depth of cuts

The evaluated generated maximum temperature from 4 mm away of tool tip at

different speed- depth of cut combinations at constant feed under dry, flood and MQL
from Figure 3(a)-(c) clearly depicts compared to dry, flood environments temperature has
been decreased under minimum quantity lubrication (MQL) at different experimental
conditions. With the increase in cutting speed and depth of cuts, maximum generated
temperature has been increased as usual, even under MQL due to increase in energy input
generated temperature increases with the increase in specific energy consumption and
material removal rate i.e. with the increase of cutting speed and depth of cuts.

3.2 Cutting force

Generally cutting forces are estimates the power consumption. In the present work, the
magnitude of Fx(Feed force) and Fz (cutting force) have been monitored by lathe tool
dynamometer for all the combinations of speeds, depth of cuts and different environments
undertaken. The effects of MQL on Fx and Fz that have been observed while turning have
been plotted shown in Figure 4 and Figure 5 respectively.

Depth of cut 0.1mm 10 Depth of cut 0.2mm

10
8 8
Force(Fx)

6 Dry 6
Force(Fx)

4 Dry
Flood 4
2 Flood
2
0 MQL
0 MQL
270 421 646 1000
270 421 646 1000
Speed(rpm)
Speed(rpm)
(a) (b)

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Journal of Huazhong University of Science and Technology ISSN-1671-4512

Depth of cut 0.3mm

10
8

Force(Fx)
6
Dry
4
Flood
2
MQL
0
270 421 646 1000
Speed(rpm)
(c)

Figure 4. Feed force (Kgf) vs Speeds (rpm) under different Depth of cuts

Depth of cut 0.1mm Depth of cut 0.2mm

25 25
20 20
Force(Fz)

15 Force(Fz) 15
D
10 10 D
F
5 F
5
M M
0 0
270 421 646 1000 270 421 646 1000
Speed(rpm) Speed(rpm)

(a) (b)
Depth of cut
0.3mm
25
20
Force(Fz)

15
10 Dry
5 Flood
0
MQL
270 421 646 1000
Speed(rpm)

(c)

Figure 5. Cutting force (Kgf) vs Speeds (rpm) under different Depth of cuts

In these investigations, two components of cutting force (main cutting force Fz and
feed force Fx) was recorded during machining under dry, flood and MQL conditions.
Figure 4& 5 clearly show that the MQL jet quite successful in reducing the main cutting
force and feed force. This is attributed to mainly the reduction of friction accomplished by
the lubricating effect of the MQL jet. The MQL jet with its velocity was able to reach the
tool tip where it performed its lubricating and cooling effects and minimized friction to a
remarkable amount. It has also been seen that main cutting forces and feed forces
decreases with the increase of cutting speed this due to thermal softening of the work

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material. However the magnitude of force component increases with the increase of depth
of cuts.

3.3 Surface roughness

Surface roughness is a widely used index of product quality and in most cases a
technical requirement for mechanical products. In this work after machining surface
roughness has been measured by a Talysurf. Variation of surface roughness at different
depth of cuts and speeds under dry, flood and MQL conditions have been plotted shown
in Figure 6.

7 Depth of Cut-0.1mm 7 Depth of Cut-0.2mm

Surface roughness (μm)

Surface roughness (μm

6 6
5 5
4 4 Dry
3 Dry 3 Flood
2 2
Flood 1 MQL
1
0 MQL 0
270 421 646 1000 270 421 646 1000
Speed(rpm) Speed(rpm)

(a) (b)

Depth of Cut-0.3mm
Surface roughness (μm)

7
6
5
4 Dry
3
2 Flood
1
0 MQL
270 421 646 1000
Speed(rpm)

(c)

Figure 6. Surface roughness (μm) vs Speeds (rpm) under different Depth of cuts

From the graphs it is seen that surface roughness is increasing with speed and depth of
cut under all fluid environments. It appears from those Figures that surface roughness
grows quite fast under dry machining due to more intensive temperature and stresses at
the tool-tips, MQL appeared to be effective in reducing surface roughness. It is clear from
the Figure 6(a)-(c) that MQL could provide improvement in surface finish to some extent.
This improvement might be due to reduction in wear and also to the fact of prevention of
built-up-edge formation. Variation of surface roughness at lower speed and depth of cut
under all selected fluid environments is very low. However it is crystal clear that from all
the results under MQL improved surface finish.

3.4 Chip formation

From the Figure 7 it is observed that tightly coiled chips are formed during MQL that
could handled easily where as short snared chips are prevalent during dry turning. It is

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clear that MQL promotes acceptable chips that can handle easily. Figure.7 shows the
photographs of chips under different fluid environments. When the machining was done
MQL environment the chips were continuous long and tightly coiled curly chips. But
while machining in wet environment the form of chips is similar to MQL environment but
comparatively low tightened medium coiled chips. In dry cutting environment, the
temperature in cutting zone increases due to which, the chips were too short and snarled
ribbon type.

Figure 7. Chip formation under different fluid environments

4. CONCLUSION
In this work the effect soybean oil based nanofluid under minimum quantity
lubrication on machining performance in turning of AISI 304 steel in terms of maximum
generated temperature, cutting forces, surface finish and chip morphology has been
examined.

 The MQL system has been proved to be successful in reduction of generated

temperature it is true that this small reduction has enabled significant improvement
in machinability indices.
 MQL has reduced the cutting force due to provided effective cooling at the shear
zone which reduced interface temperature. During machining cutting forces were
decreased as the cutting speed increases. The cutting forces are increased as the
feed and depth of cut are increased for various cutting conditions.
 MQL provided proper lubrication that minimizes the friction resulting in retention
of tool sharpness for a longer period which leads lower surface roughness values
were obtained.
 It is observed that tightly coiled chips are formed during MQL turning and during
that could handled easily where as short snared chips are prevalent during dry
turning. The chips formed during flood were similar to that during MQL turning in
spite of fluid application. It is clear that MQL promotes acceptable chips that can
handle easily.

5. REFERENCES

[1] Phafat, Deshmukh and Deshmukh ,“Study of Cutting Parameters Effects in MQL-Employed Hard-
Milling Process for AISI H13 for Tool Life. In Applied Mechanics and Materials”, Trans Tech Publ.:
Zurich, Switzerland, (2013), pp.240–245.
[2] Dhar and Kamruzzaman, Ahmed, “Effect of minimum quantity lubrication (MQL) on tool wear and
surface roughness in turning AISI-4340 steel”, J. Mater. Process. Technol., (2006), pp. 299–304.
[3] Khan, Mithu, Dhar, “Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using
vegetable oil based cutting fluid”, J. Mater. Process. Technol., Vol.209, (2009), pp. 5573–5583.
[4] Weinert, Inasaki, Sutherland and Wakabayashi, “Dry machining and minimum quantity lubrication”,
CIRP Ann. Manuf. Technol., Vol.53, (2004), pp. 511–537.
[5] Dhar; Kamruzzaman; Ahmed, “ Effect of minimum quantity lubrication (MQL) on tool wear and
surface roughness in turning AISI-4340 steel”, J. Mater. Process. Technol., Vol.172, (2006), pp. 299–
304.

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[6] Khan, Mithu, Dhar, “Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using
vegetable oil based cutting fluid”, J. Mater. Process. Technol., Vol. 209, (2009), pp. 5573–5583.
[7] Weinert, Inasaki, Sutherland, Wakabayashi, “Dry machining and minimum quantity lubrication”,
CIRP Ann. Manuf. Technol., Vol.53, (2004), pp. 511–537.
[8] Dhar, Islam, Islam, Mithu, “The influence of minimum quantity of lubrication (MQL) on cutting
temperature, chip and dimensional accuracy in turning AISI-1040 steel”, J. Mater. Process. Technol.,
Vol. 171, (2006), pp. 93–99.
[9] Kang, Kim, Shin, Jang, Park, Kim, “Effect of the minimum quantity lubrication in high-speed end-
milling of AISI D2 cold-worked die steel (62 HRC) by coated carbide tools”, Surf. Coat. Technol.,
Vol.202, (2008), pp. 5621–5624.
[10] Liang, Ronan, “Minimum Quantity Lubrication in Finish Hard Turning”, Georgia Institute of
Technology: Atlanta, GA, (2003), USA.
[11] Iqbal, He, Li ,“Empirical modeling the effects of cutting parameters in high speed end milling of
hardened AISI D2 under MQL environment”, In Proceedings of the World Congress on Engineering,
London, (2011), UK.
[12] P. Nageswara Rao, Suresh BabuValeru and K.N.S Suman, “Improvement of desirable
thermophysical properties of soybean oil for metal cutting applications as a cutting fluid”, Advances
in Science, Technology and Engineering Systems Journal, Vol. 5, No. 3, (2020), pp.129-134.
[13] Suresh Babu Valeru, P. Nageswara Rao and K.N.S Suman, “Optimization of Vegetable Oil
Properties in Machining Environment Through CFD”, International Journal of Innovative Technology
and Exploring Engineering (IJITEE), Vol. 8, no 12, (2019).

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