Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects
Shuguo HU1, Changhe LI1(), Zongming ZHOU2, Bo LIU3, Yanbin ZHANG1, Min YANG1, Benkai LI1, Teng GAO1, Mingzheng LIU1, Xin CUI1, Xiaoming WANG1, Wenhao XU1, Y. S. DAMBATTA1,4, Runze LI5, Shubham SHARMA1,6
1. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China 2. Hanneng (Qingdao) Lubrication Technology Co., Ltd., Qingdao 266100, China 3. Sichuan New Aviation TA Technology Co., Ltd., Shifang 618400, China 4. Mechanical Engineering Department, Ahmadu Bello University, Zaria 810106, Nigeria 5. Massachusetts Institute of Technology, Cambridge, MA 02139, USA 6. Department of Mechanical Engineering, IK Gujral Punjab Technical University, Punjab 144603, India
Nanoparticle-enhanced coolants (NPECs) are increasingly used in minimum quantity lubrication (MQL) machining as a green lubricant to replace conventional cutting fluids to meet the urgent need for carbon emissions and achieve sustainable manufacturing. However, the thermophysical properties of NPEC during processing remain unclear, making it difficult to provide precise guidance and selection principles for industrial applications. Therefore, this paper reviews the action mechanism, processing properties, and future development directions of NPEC. First, the laws of influence of nano-enhanced phases and base fluids on the processing performance are revealed, and the dispersion stabilization mechanism of NPEC in the preparation process is elaborated. Then, the unique molecular structure and physical properties of NPECs are combined to elucidate their unique mechanisms of heat transfer, penetration, and anti-friction effects. Furthermore, the effect of NPECs is investigated on the basis of their excellent lubricating and cooling properties by comprehensively and quantitatively evaluating the material removal characteristics during machining in turning, milling, and grinding applications. Results showed that turning of Ti‒6Al‒4V with multi-walled carbon nanotube NPECs with a volume fraction of 0.2% resulted in a 34% reduction in tool wear, an average decrease in cutting force of 28%, and a 7% decrease in surface roughness Ra, compared with the conventional flood process. Finally, research gaps and future directions for further applications of NPECs in the industry are presented.
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