Hybrid nano-fluid-minimum quantity lubrication strategy for machining austempered ductile iron (ADI): Fid-Bau Portal

Hybrid nano-fluid-minimum quantity lubrication strategy for machining austempered ductile iron (ADI)

Eltaggaz, A. / Hegab, H. / Deiab, I. / Kishawy, H. A.

Abstract The use of austempered ductile iron (ADI) is rapidly increasing in many engineering applications such as automotive due to its unique and promising characteristics, for example; high strength to weight ratio, high wear and corrosion resistance, high yield stress, and high toughness. However, other properties such as low thermal conductivity undesirably affects ADI machinability and accelerate cutting tool failure. Additionally, other issues associated with cutting ADI are the high cutting temperature, high pressure and dynamic loads, and tendency of chip to adhere to cutting tool face. To overcome such issues, a proper coolant should be applied. However, flood coolant has sufficient effects in reducing the generated cutting heat, further alternatives are still required to decease its environmental and health impacts. Minimum quantity lubrication (MQL) serves as the best alternative to flood cooling from an environmental perspective as it minimizes the amount of cutting fluid; however, its heat capacity is lower than the traditional flood coolant. To improve the cooling and lubricating efficiency of MQL, aluminum oxide ( ${Al}_{2} O_{3}$ ) gamma nanoparticles are used in this work and its effect on the tool wear behavior during cutting of ADI is investigated. The combination of MQL-nanofluid at cutting speed of 120 m/min and feed rate of 0.2 mm/rev showed the best tool life, while test 3 which has been performed at cutting speed of 240 m/min and feed rate of 0.2 mm/rev using classical MQL provided the worst flank wear value.