Cryogenic minimum quantity lubrication machining: from mechanism to application

Abstract

Cutting fluid plays a cooling–lubrication role in the cutting of metal materials. However, the substantial usage of cutting fluid in traditional flood machining seriously pollutes the environment and threatens the health of workers. Environmental machining technologies, such as dry cutting, minimum quantity lubrication (MQL), and cryogenic cooling technology, have been used as substitute for flood machining. However, the insufficient cooling capacity of MQL with normal-temperature compressed gas and the lack of lubricating performance of cryogenic cooling technology limit their industrial application. The technical bottleneck of mechanical–thermal damage of difficult-to-cut materials in aerospace and other fields can be solved by combining cryogenic medium and MQL. The latest progress of cryogenic minimum quantity lubrication (CMQL) technology is reviewed in this paper, and the key scientific issues in the research achievements of CMQL are clarified. First, the application forms and process characteristics of CMQL devices in turning, milling, and grinding are systematically summarized from traditional settings to innovative design. Second, the cooling–lubrication mechanism of CMQL and its influence mechanism on material hardness, cutting force, tool wear, and workpiece surface quality in cutting are extensively revealed. The effects of CMQL are systematically analyzed based on its mechanism and application form. Results show that the application effect of CMQL is better than that of cryogenic technology or MQL alone. Finally, the prospect, which provides basis and support for engineering application and development of CMQL technology, is introduced considering the limitations of CMQL.

Graphical abstract

Keywords

cryogenic minimum quantity lubrication (CMQL) / cryogenic medium / processing mode / device application / mechanism / application effect

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Nomenclature

Abbreviations
BUE	Build-up edge
BUL	Build-up layer
CA	Cryogenic air
CMQL	Cryogenic minimum quantity lubrication
CNMQL	Cryogenic nanoparticle minimum quantity lubrication
DHC	Double-helix channel
DL	Dissolved lubricant in scCO2
DSC	Double straight channel
hBN	Hexagonal boron nitride
HRE	Heat removal efficiency
HRP	Heat removal potential
LCO2	Liquid carbon dioxide
LN2	Liquid nitrogen
MQL	Minimum quantity lubrication
MWCNT	Multiwalled carbon nanotube
NDL	No dissolved lubricant
NMQL	Nanoparticle minimum quantity lubrication
Oow	Oil-on-water
scCO2	Supercritical carbon dioxide
SEM	Scanning electron microscope
SSC	Single straight channel

XL	Lubricant expanded with scCO2
Variables
ae	Milling width, mm
ap	Depth of cutting, mm
A	Heat transfer area, m2
d	Diameter of channel, mm
f	Feed rate, mm
fz	Milling feed rate, mm/tooth
F1	Surface tension under CMQL, N
F2	Surface tension under MQL, N
h	Heat transfer coefficient, W/(m2·K)
h1	Oil film thickness under CMQL, mm
h2	Oil film thickness under MQL, mm
Pc	Pressure of MQL, MPa
P0	Surface pressure, MPa
P∞	External environment pressure, MPa
q	Heat flux, W/m
Q	Flow rate, mL/min
r	Radius of a curved surface, mm
R	Diameter of droplets, mm
S1	Spreading length under CMQL, mm
S2	Spreading length under MQL, mm
t	Time, s
th	Thickness of the outlet section, mm
T0	Temperature, °C
T1	Temperature under CMQL, °C
T2	Temperature under MQL, °C
u	Velocity at a tangent, m/s
vc	Cutting speed, m/min
vf	Feed speed, mm/rev
V1	Viscosity at T1, Pa·s
V2	Viscosity at T2, Pa·s
ΔT	Temperature difference, °C
θ1	Contact angle under CMQL, (° )
θ2	Contact angle under MQL, (° )
ρ	Fluid density, kg/m3

Acknowledgements

This paper was financially supported by the National Natural Science Foundation of China (Grant Nos. 51975305 and 51905289), the Key Project of Shandong Province, China (Grant No. ZR2020KE027), the Major Research Project of Shandong Province, China (Grant Nos. 2019GGX104040 and 2019GSF108236), the Natural Science Foundation of Shandong Province, China (Grant No. ZR2020ME158), and the Applied Basic Research Youth Project of Qingdao Science and Technology Plan, China (Grant No. 19-6-2-63-cg).

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