Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant

doi:10.1007/s11465-022-0719-x

Front. Mech. Eng.

2023, Vol. 18

Issue (1) : 3 https://doi.org/10.1007/s11465-022-0719-x

REVIEW ARTICLE

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant

Xin CUI¹, Changhe LI¹(

), Yanbin ZHANG²(

), Wenfeng DING³, Qinglong AN⁴, Bo LIU⁵, Hao Nan LI⁶, Zafar SAID⁷, Shubham SHARMA⁸, Runze LI⁹, Sujan DEBNATH¹⁰

¹. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China
². State Key Laboratory of Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, China
³. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
⁴. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
⁵. Sichuan Future Aerospace Industry LLC., Shifang 618400, China
⁶. School of Aerospace, University of Nottingham Ningbo China, Ningbo 315100, China
⁷. College of Engineering, University of Sharjah, Sharjah 27272, United Arab Emirates
⁸. Department of Mechanical Engineering, IK Gujral Punjab Technical University, Punjab 144603, India
⁹. Department of Biomedical Engineering, University of Southern California, Los Angeles, CA 90089, USA
¹⁰. Mechanical Engineering Department, Curtin University, Miri 98009, Malaysia

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Abstract

The substitution of biolubricant for mineral cutting fluids in aerospace material grinding is an inevitable development direction, under the requirements of the worldwide carbon emission strategy. However, serious tool wear and workpiece damage in difficult-to-machine material grinding challenges the availability of using biolubricants via minimum quantity lubrication. The primary cause for this condition is the unknown and complex influencing mechanisms of the biolubricant physicochemical properties on grindability. In this review, a comparative assessment of grindability is performed using titanium alloy, nickel-based alloy, and high-strength steel. Firstly, this work considers the physicochemical properties as the main factors, and the antifriction and heat dissipation behaviours of biolubricant in a high temperature and pressure interface are comprehensively analysed. Secondly, the comparative assessment of force, temperature, wheel wear and workpiece surface for titanium alloy, nickel-based alloy, and high-strength steel confirms that biolubricant is a potential replacement of traditional cutting fluids because of its improved lubrication and cooling performance. High-viscosity biolubricant and nano-enhancers with high thermal conductivity are recommended for titanium alloy to solve the burn puzzle of the workpiece. Biolubricant with high viscosity and high fatty acid saturation characteristics should be used to overcome the bottleneck of wheel wear and nickel-based alloy surface burn. The nano-enhancers with high hardness and spherical characteristics are better choices. Furthermore, a different option is available for high-strength steel grinding, which needs low-viscosity biolubricant to address the debris breaking difficulty and wheel clogging. Finally, the current challenges and potential methods are proposed to promote the application of biolubricant.

Keywords grinding aerospace difficult-to-machine material biolubricant physicochemical property grindability

Corresponding Author(s): Changhe LI,Yanbin ZHANG

Just Accepted Date: 13 July 2022 Issue Date: 02 December 2022

Cite this article:

Xin CUI,Changhe LI,Yanbin ZHANG, et al. Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant[J]. Front. Mech. Eng., 2023, 18(1): 3.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-022-0719-x
https://academic.hep.com.cn/fme/EN/Y2023/V18/I1/3

Fig.1 Distribution of costs in the automobile industry. Reproduced with permission from Refs. [7,8] from Elsevier.

Fig.2 Paper structure.

Fig.3 Grinding mechanisms using a biolubricant. CoF: coefficient of friction.

Tab.1 Chemical composition of Ti–6Al–4V

Tab.2 Mechanical properties of Ti–6Al–4V

Fig.4 Improvement ratio of biolubricant MQL compared with the traditional flood or dry grinding [89–91].

Fig.5 Lubricant film observation by EDS analysis. Reproduced with permission from Ref. [91] from Elsevier.

Fig.6 Grinding wheel wear under different lubrication conditions. Reproduced with permission from Ref. [93] from Elsevier.

Fig.7 Debris morphology under different lubrication conditions: (a) dry grinding (×200), (b) dry grinding (×700), (c) synthetic esters (×200), and (d) synthetic esters (×700). Reproduced with permission from Ref. [102] from Elsevier.

Fig.8 Surface and cross-section morphology under different lubrication conditions: cross-section scanning electron microscopy (SEM) under (a) flood, (b) vegetable oil, and (c) synthetic esters; surface SEM under (d) flood, (e) vegetable oil, and (f) synthetic esters. Reproduced with permission from Ref. [89] from Springer Nature.

Tab.3 Grinding conditions and experimental results of titanium alloy [89–93,96,102]

Tab.4 Chemical composition of Inconel 718

Tab.5 Mechanical properties of Inconel 718

Fig.9 Improvement ratio of biolubricant MQL compared with the traditional conditions [107–110].

Fig.10 Morphology and EDS analysis of the grinding wheel: (a) before grinding, (b) after grinding, and (c) EDS analysis. Reproduced with permission from Ref. [116] from Elsevier.

Fig.11 Debris morphology under different lubrication conditions: (a) flood, (b) MQL with palm oil, (c) palm oil + Al₂O₃, and (d) palm oil + nanodiamond. Reproduced with permission from Ref. [121] from Elsevier.

Fig.12 Surface SEM and EDS analysis of Ni-based alloy using Al₂O₃ biolubricant: (a) sunflower oil + Al₂O₃ [107], (b) soybean oil + Al₂O₃ [122], and (c) palm oil + Al₂O₃ [116]. Reproduced with permission from Refs. [107,116,122] from Elsevier.

Ref.	Lubricant	Nano-enhancer	Evaluation parameters	Conclusions
[107]	Sunflower oil and rice bran oil	Al₂O₃	Force, CoF, specific grinding energy, G-ratio, grinding temperature, surface roughness, and workpiece surface topography	1. Sunflower oil > rice bran oil2. Under Al₂O₃ NMQL, optimal results are obtained
[108]	Peanut oil and palm oil	Al₂O₃	CoF, specific grinding energy, and G-ratio	1. Palm oil > peanut oil > flood2. Al₂O₃ NMQL > MQL
[109]	Paraffin, soybean oil, peanut oil, corn oil, rapeseed oil, palm oil, castor oil, and sunflower oil	–	CoF, specific grinding energy, G-ratio, surface roughness, and workpiece surface topography	1. Vegetable oil > paraffin2. Castor oil is the best
[110]	Castor oil, soybean oil, rapeseed oil, corn oil, peanut oil, palm oil, and sunflower oil	–	Force and grinding temperature	1. Castor oil has the lowest force2. Palm oil has the lowest grinding temperature, and castor oil has the highest
[111]	Palm oil and castor oil	Al₂O₃ + SiC	Force, specific grinding energy, and surface roughness	Palm oil > castor oil
[112]	Palm oil	Al₂O₃, MoS₂	CoF, specific grinding energy, G-ratio, debris, surface roughness, and workpiece surface topography	Al₂O₃ NMQL > MoS₂ NMQL > palm oil MQL
[113]	Synthetic esters	CNT, MoS₂	Force	Hybrid nano-enhancers > single nano-enhancer
[114]	Vegetable oil	Al₂O₃, SiC	Force	Hybrid nano-enhancers > single nano-enhancer
[115]	Vegetable oil	Al₂O₃, SiC	Force	Optimal particle size ratio is Al₂O₃:SiC = 7:3
[116]	Palm oil	Al₂O₃	Specific grinding energy, G-ratio, debris, and workpiece surface topography	1. Optimal Al₂O₃ concentration (specific grinding energy) is 1.5 vol.%2. Optimal Al₂O₃ concentration (G-ratio) is 2.5 vol.%
[117]	Palm oil	CNT	Force and grinding temperature	Optimal CNT concentration is 2 vol.%
[118]	Vegetable oil	MWCNT and Al₂O₃	Wheel wear	MWCNT NMQL > Al₂O₃ NMQL
[119]	Liquid paraffin, palm oil, rapeseed oil, and soybean oil	MoS₂	Force, CoF, and specific grinding energy	Palm oil is the optimum base oil of MQL
[120]	Palm oil	MoS₂, SiO₂, PCD, CNT, Al₂O₃, and ZrO₂	Grinding temperature, surface roughness, and working surface topography	CNT NMQL is optimal
[121]	Palm oil	Al₂O₃	Debris morphology	Al₂O₃ NMQL > palm oil MQL > flood
[122]	Soybean oil	Al₂O₃	Surface roughness and workpiece surface topography	Optimal Al₂O₃ concentration is 2 wt.%
[123]	Palm oil	CNT	Workpiece surface topography	Optimal CNT concentration is 2 vol.%
[124]	Synthetic esters	Al₂O₃, MoS₂	Surface roughness	Hybrid nano-enhancers > single nano-enhancer

Tab.6 Grinding conditions and experimental results of Inconel 718 [107–124]

Tab.7 Chemical composition of high-strength steels

Tab.8 Mechanical properties of high-strength steels

Fig.13 Grinding performance of high-strength steel using biolubricant [127–132].

Fig.14 Diametric wheel wear using vegetable oil + water hybrid lubricant [133].

Fig.15 SEM of the grinding wheel under different lubrication conditions. Reproduced with permission from Ref. [134] from Elsevier.

Fig.16 Cross-sectional morphology under different lubrication conditions: (a) dry grinding, (b) MQL using water, and (c) MQL using water-based nano-lubricant. Reproduced with permission from Ref. [129] from Springer Nature.

Fig.17 Debris morphology under different lubrication conditions. Reproduced with permission from Ref. [134] from Elsevier.

Fig.18 Debris morphology under different lubricants and usage amounts: (a) sunflower oil, 500 mL/h, (b) sunflower oil + CNT, 500 mL/h, (c) sunflower oil + CNT, 200 mL/h, and (d) sunflower oil + CNT, 50 mL/h. Reproduced with permission from Ref. [130] from Elsevier.

Fig.19 Residual stress of workpiece under different lubrication conditions. Reproduced with permission from Ref. [130] from Elsevier.

Fig.20 Surface and cross-sectional morphology under different lubrication conditions. Cross-section: (a) flood, (b) dry grinding, (c) MQL using synthetic oil, and (d) MQL using vegetable oil. Surface: (e) flood, (f) dry grinding, (g) MQL using synthetic oil, and (h) MQL using vegetable oil. Reproduced with permission from Ref. [127] from Springer Nature.

Fig.21 Surface integrity under various usage amounts and with or without WCJ method: (a) MQL (40 mL/h), (b) MQL (80 mL/h), (c) MQL (160 mL/h), (d) MQL + WCJ (40 mL/h), (e) MQL + WCJ (80 mL/h), and (f) MQL + WCJ (160 mL/h). Reproduced with permission from Ref. [136] from Springer Nature.

Tab.9 Grinding conditions and experimental results of high-strength steel [127–136]

Fig.22 Yearbook of grinding aerospace materials with biolubricants [89–92,96,107–119,121–124,127,128,130,132–140].

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