Magnetic field distribution mechanism and grindability in magnetic traction nano-lubricant grinding of Ti-6Al-4V

Abstract

Nano-lubricant minimum quantity lubrication (NMQL) is an eco-friendly precision technology used for grinding challenging aerospace materials. However, its film-forming ability and anti-friction performance in high-speed and high-pressure grinding zones cannot satisfy the processing requirements. To address this limitation, a novel method using magnetic traction nano-lubricant was investigated. By applying an external magnetic field, a gradient magnetic field is formed on the surface of the grinding wheel to absorb the magnetic lubricant and improve the infiltration performance. A permanent magnet was used to magnetize the grinding wheel matrix, thereby directing the magnetic flux lines and guiding the distribution of the magnetic field through the grinding wheel. Hence, the magnetic field distribution was numerically simulated by adjusting the distribution, geometric position, and parameters of the permanent magnet. In type I (wherein there is repulsion between the N-S poles on the left and right), a uniform and strong magnetic field can be generated when L=6–16 mm, β=0°–30°, and H is suitably increased. This set up can achieve a maximum magnetic field intensity of 1.1×10⁵ A/m. Furthermore, the impact of the geometrical parameters (L, H, and β) of the magnetic-assisted device on the grindability of Ti-6Al-4V was examined using an orthogonal experiment. The optimum parameters for the permanent magnet arrangement and the geometric position were L=12 mm, H=10 mm, and β=0°, thereby resulting in a smoother workpiece with fewer defects.

Keywords

Magnetic traction nano-lubrication / Minimum quantity lubrication / Grindability / Anti-friction mechanism / Titanium alloy

References

[1] Gong P, Zhang YB, Wang CJet al.. Residual stress generation in grinding: mechanism and modeling. J Mater Process Tech, 2024, 324: 39

[2] Liu MZ, Li CH. Thermodynamic mechanism of cryogenic air minimum quantity lubrication grinding. IGI Global Scientific Publishing, Hershey, Pennsylvania, USA, 2024

[3] Siju AS, Waigaonkar SD. Effects of rake surface texture geometries on the performance of single-point cutting tools in hard turning of titanium alloy. J Manuf Process, 2021, 69: 235-252

[4] Lindvall R, Lenrick F, Andersson JMet al.. On wear of TiAlN coated tools with and without NbN overlayer in machining titanium alloys. Int J Mach Tool Manu, 2024, 198 104148

[5] Li B, Ding W, Zhu Yet al.. Design and grindability assessment with cup shaped electroplated CBN wheel grinding turbine disc slots of powder metallurgy superalloy FGH96. Chin J Aeronaut, 2023, 37(9): 521-534

[6] Li LY, Zhang YB, Cui Xet al.. Mechanical behavior and modeling of grinding force: a comparative analysis. J Manuf Process, 2023, 102: 921-954

[7] Li C, Wang K, Piao Yet al.. Surface micro-morphology model involved in grinding of GaN crystals driven by strain-rate and abrasive coupling effects. Int J Mach Tool Manu, 2024, 201 104197

[8] Deng W, Lu H, Wang Cet al.. Dual skin effect and deep heterostructure of titanium alloy subjected to high-frequency electropulsing-assisted laser shock peening. Int J Mach Tool Manu, 2024, 201 104196

[9] Yang S, Jin X, Engin Set al.. Effect of cutting fluids on surface residual stress in machining of waspaloy. J Mater Process Tech, 2023, 322 118170

[10] Chen J, Liu D, Jin Tet al.. A novel bionic micro-textured tool with the function of directional cutting-fluid transport for cutting titanium alloy. J Mater Process Tech, 2023, 311 117816

[11] Xing Y, Luo C, Zhu Met al.. Assessment of self-lubricating coated cutting tools fabricated by laser additive manufacturing technology for friction-reduction. J Mater Process Tech, 2023, 318 118010

[12] Tawakoli T, Hadad M, Sadeghi MHet al.. Minimum quantity lubrication in grinding: effects of abrasive and coolant-lubricant types. J Clean Prod, 2011, 19(17/18): 2088-2099

[13] Xu W, Li C, Cui Xet al.. Atomization mechanism and machinability evaluation with electrically charged nanolubricant grinding of GH4169. J Manuf Process, 2023, 106: 480-493

[14] Shao Y, Fergani O, Li Bet al.. Residual stress modeling in minimum quantity lubrication grinding. Int J Adv Manuf Technol, 2016, 83: 743-751

[15] Zhang Y, Li HN, Li Cet al.. Nano-enhanced biolubricant in sustainable manufacturing: from processability to mechanisms. Friction, 2022, 10(6): 803-841

[16] He T, Liu N, Xia Het al.. Progress and trend of minimum quantity lubrication (MQL): a comprehensive review. J Clean Prod, 2023, 386 135809

[17] Nouzil I, Drummond M, Eltaggaz Aet al.. Experimental and numerical investigation of cooling effectiveness of nano minimum quantity lubrication. J Manuf Process, 2023, 108: 418-429

[18] Yang M, Ma H, Hao JCet al.. Droplet size distribution model of needle electrode electrostatic atomization and milling nickel-based alloy performance evaluation. J Manuf Process, 2024, 119: 682-698

[19] Mao C, Tang X, Zou Het al.. Investigation of grinding characteristic using nanofluid minimum quantity lubrication. Int J Precis Eng Manuf, 2012, 13: 1745-1752

[20] Cui X, Li C, Zhang Yet al.. Grindability of titanium alloy using cryogenic nanolubricant minimum quantity lubrication. J Manuf Process, 2022, 80: 273-286

[21] Singh H, Sharma VS, Dogra M. Exploration of graphene assisted vegetables oil based minimum quantity lubrication for surface grinding of Ti-6Al-4V-ELI. Tribol Int, 2020, 144 106113

[22] Singh H, Sharma VS, Singh Set al.. Nanofluids assisted environmental friendly lubricating strategies for the surface grinding of titanium alloy: Ti6Al4V-ELI. J Manuf Process, 2019, 39: 241-249

[23] Li M, Yu T, Zhang Ret al.. Experimental evaluation of an eco-friendly grinding process combining minimum quantity lubrication and graphene-enhanced plant-oil-based cutting fluid. J Clean Prod, 2020, 244 118747

[24] Ibrahim AMM, Li W, Xiao Het al.. Energy conservation and environmental sustainability during grinding operation of Ti-6Al-4V alloys via eco-friendly oil/graphene nano additive and Minimum quantity lubrication. Tribol Int, 2020, 150 106387

[25] Cui X, Li C, Yang Met al.. Enhanced grindability and mechanism in the magnetic traction nanolubricant grinding of Ti-6Al-4V. Tribol Int, 2023, 186 108603

[26] Dambatta YS, Li CH, Sayuti Met al.. Grindability evaluation of ultrasonic assisted grinding of silicon nitride ceramic using minimum quantity lubrication based SiO₂ nanofluid. Chin J Mech Eng, 2024, 37(1): 22

[27] Shang W, Cai T, Zhang Yet al.. Facile one pot pyrolysis synthesis of carbon quantum dots and graphene oxide nanomaterials: all carbon hybrids as eco-environmental lubricants for low friction and remarkable wear-resistance. Tribol Int, 2018, 118: 373-380

[28] Gong K, Wu X, Zhao Get al.. Nanosized MoS₂ deposited on graphene as lubricant additive in polyalkylene glycol for steel/steel contact at elevated temperature. Tribol Int, 2017, 110: 1-7

[29] Wu P, Chen X, Zhang Cet al.. Synergistic tribological behaviors of graphene oxide and nanodiamond as lubricating additives in water. Tribol Int, 2019, 132: 177-184

[30] Ku B, Han Y, Lee Jet al.. Tribological effects of fullerene (C-60) nanoparticles added in mineral lubricants according to its viscosity. Int J Precis Eng Manuf, 2010, 11(4): 607-611

[31] Li R, Lu T. The influence of carbon nanotubes and graphene as additives in lubricant oil on friction and wear. China Sciencepaper, 2015, 10(10): 1123-1126

[32] Pu J, Wang L, Xue Q. Progress of tribology of graphene and graphene-based composite lubricating materials. Tribology, 2014, 34(1): 93-112

[33] Song YX, Li CH, Zhou ZMet al.. Nanobiolubricant grinding: a comprehensive review. Adv Manuf, 2024, 13(1): 1-42

[34] Wang J, Guo X, He Yet al.. Tribological characteristics of graphene as grease additive under different contact forms. Tribol Int, 2018, 127: 457-469

[35] Li Q, Zhang S, Qi Yet al.. Friction of two-dimensional materials at the nanoscale: behavior and mechanisms. Chin J Solid Mech, 2017, 38(3): 189-214

[36] Cheng J, Xie F, Li B. Application of nano-carbon lubricating oil additives. Contemp Chem Ind, 2016, 45(4): 843-846

[37] Li Z, Zhang Y, He Qet al.. Research progress on the application of grapheme as additives in lubrication. Lubr Eng, 2017, 42(10): 133-140

[38] Zhang S, Wang K, Hu Z. Effect of graphene additive on tribological properties of lube base oil. Pet Process Petrochem, 2018, 49(9): 91-95

[39] Dambatta YS, Li CH, Yang Met al.. Grinding with minimum quantity lubrication: a comparative assessment. Int J Adv Manuf Technol, 2023, 128(3/4): 955-1014

[40] Zhang XT, Li CH, Zhou ZMet al.. Vegetable oil-based nanolubricants in machining: from physicochemical properties to application. Chin J Mech Eng, 2023, 36(1): 39

[41] Guo S, Li C, Zhang Yet al.. Experimental evaluation of the lubrication performance of mixtures of castor oil with other vegetable oils in MQL grinding of nickel-based alloy. J Clean Prod, 2017, 140: 1060-1076

[42] Liu D, Li C, Xu Pet al.. SiCp/Al composites from conventional to empowered machining: mechanisms and processability. Compos Struct, 2024

[43] Gong P, Zhang YB, Cui Xet al.. Lubricant transportation mechanism and wear resistance of different arrangement textured turning tools. Tribol Int, 2024, 196: 22

[44] Ming WY, Shen F, Zhang Zet al.. A comparative investigation on magnetic field-assisted EDM of magnetic and non-magnetic materials. Int J Adv Manuf Technol, 2020, 109(3/4): 1103-1116

[45] Zhang Z, Zhang Y, Ming WYet al.. A review on magnetic field assisted electrical discharge machining. J Manuf Process, 2021, 64: 694-722

[46] Jain VK. Magnetic field assisted abrasive based micro-/nano-finishing. J Mater Process Tech, 2009, 209(20): 6022-6038

[47] Cheng CP, Wu KL, Mai CCet al.. Magnetic field-assisted electrochemical discharge machining. J Micromech Microeng, 2010, 20(7): 7

[48] Bains PS, Sidhu SS, Payal HS. Investigation of magnetic field-assisted EDM of composites. Mater Manuf Process, 2018, 336670-675

[49] Huang YS, Zhao BS, Huang SQet al.. Pulse electromagnetic field-assisted chemical mechanical polishing utilizing magnetic composite abrasives slurry and its polishing performance. China Mech Eng, 2014, 25(9): 1175-1238

[50] Xu XF, Guo Q, Huang YSet al.. Chemical mechanical polishing using magnetic composite abrasives slurry and experimental study on polishing performance. China Mech Eng, 2011, 47(21): 186-192

[51] Hirose E, Tanaka KH, Takahashi Tet al.. A new 3-axis magnetic field measurement system based on hall elements. IEEE Trans Appl Supercond, 2004, 14(2): 1814-1817

[52] Chen JZ, Zhang YM. The design for auto-instrument of magnet field measurement. Modern Manuf Eng, 2003, 2003(11): 58-59

[53] Chen DX, Pan MC, Luo FLet al.. The air gap magnetic fields measurement of high speed magnetic levitation vehicle. Electrotech Appl, 2003, 12: 69-70

[54] Wang XM, Wang Y, Wang GY. The systam for measuring and analyzing superficial magnetic field of pemanent magnet. Small & Special Electric Mach, 2005, 33(10): 9-11

[55] Wang C, Yang WY, Zhai GFet al.. Research on 3D measuring system of magnetic fiekd of small permanent magnet. Low Voltage Appar, 2009, 9: 28-31

[56] Huang DY, Zhang T, Han Bet al.. Influence of applied stress and residual stress on coercive force of Q235 mild steel. J Magn Mater Dev, 2009, 40(6): 48-50

[57] Liu RJ, Zhang YW, Wen CWet al.. Study on the design and analysis methods of orthogonal experiment. Exp Technol Manag, 2010, 27(9): 52-55

[58] Zhong H, Bai WS, Hou ZJet al.. Research of increasing the magnetic fi eld strength by connecting the same pole together. China Modern Education Equip, 2014, 3: 67-69

[59] Fratila D, Caizar C. Application of Taguchi method to selection of optimal lubrication and cutting conditions in face milling of AlMg₃. J Clean Prod, 2011, 19(6/7): 640-645

[60] Pal RK, Garg H, Sarepaka RVet al.. Experimental investigation of material removal and surface roughness during optical glass polishing. Mater Manuf Process, 2016, 31(12): 1613-1620

[61] Cetin MH, Ozcelik B, Kuram Eet al.. Evaluation of vegetable based cutting fluids with extreme pressure and cutting parameters in turning of AISI 304L by Taguchi method. J Clean Prod, 2011, 19(17/18): 2049-2056

[62] Wang QY, Liang ZQ, Bai SWet al.. Power spectrum density characterization of grinding wheel surface in ultrasonic vibration spiral grinding. Diamond Abrasives Eng, 2021, 41(1): 58-64

[63] Yu G, Li P, Zhao QLet al.. Characterization of ultra-precision machined surfaces with power spectral density. J Harbin Instit Technolgy, 2010, 42(1): 29-32

[64] Wan M, Feng J, Ma YCet al.. Identification of milling process damping using operational modal analysis. Int J Mach Tool Manu, 2017, 122: 120-131

Funding

National Natural Science Foundation of China(52105457)

Special Fund of Taishan Scholars Project(tsqn202211179)

Young Talent of Lifting engineering for Science and Technology in Shandong, China(SDAST2021qt12)

RIGHTS & PERMISSIONS

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature