Experimental investigation of nanofluid lubrication on surface roughness under MQL aluminum alloy 6061-T6 series in drilling

Purpose

This study aims to investigate the impact of varying the number of minimum quantity lubrication (MQL) nozzles, wind pressure, spindle speed and type of lubrication on surface roughness, fatigue life and tool wear in the drilling of aluminum alloy 6061-T6.

Design/methodology/approach

The effect of using different lubricants such as palm oil, graphene/water nanofluid and SiO₂/water in the MQL method was compared with flood and dry methods. The lubricant flow and feed rate were kept constant throughout the drilling, while the number of nozzles, wind pressure and spindle speed varied. After preparing the parts, surface roughness, fatigue life and tool wear were measured, and the results were analyzed by ANOVA.

Findings

The results showed that using MQL with four nozzles and graphene/water nanofluid reduced surface roughness by 60%, followed by SiO₂ nanofluid at 56%, and then by palm oil at 50%. Increasing the spindle speed in MQL mode with four nozzles using graphene nanofluid decreased surface roughness by 52% and improved fatigue life by 34% compared to the dry mode. SEM results showed that tool wear and deformation rates significantly decreased. Increasing the number of nozzles caused the fluid particles to penetrate the cutting area, resulting in improved tool cooling with lubrication in all directions.

Originality/value

Numerous attempts have been made worldwide to eliminate industrial lubricants due to environmental pollution. In this research, using nanofluid with wind pressure in MQL reduces environmental impacts and production costs while improving the quality of the final workpiece more than flood and dry methods.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2024-0021/