Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Abstract

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.

Graphical abstract

Keywords

nanoparticle-enhanced coolant / minimum quantity lubrication / biolubricant / thermophysical properties / turning / milling / grinding

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Nomenclature

BUE	Built-up edge
CBN	Cubic boron nitride
CHTC	Convective heat transfer coefficient
CNT	Carbon nanotube
COF	Coefficient of friction
CTAB	Cetyltrimethylammonium bromide
EG	Ethylene glycol
GA	Gum Arabic
GMQL	Graphene minimum quantity lubrication
GNP	Graphene
GradT	Temperature gradient
HBN	Hexagonal boron nitride
MQL	Minimum quantity lubrication
MWCNT	Multi-walled carbon nanotube
ND	Diamond
NPEC	Nanoparticle-enhanced coolant
PCD	Polycrystalline diamond
PMQL	Pure minimum quantity lubrication
PTFE	Polytetrafluoroethylene
SDBS	Sodium dodecylbenzene sulfonate
SDS	Sodium dodecyl sulfate
SEM	Scanning electron microscope
TCIT	Tool–chip interface

Acknowledgements

This study was financially supported by the National Key R&D Program of China (Grant No. 2020YFB2010500), the National Natural Science Foundation of China (Grant Nos. 52105457 and 51975305), the Special Fund of Taishan Scholars Project, China (Grant No. tsqn202211179), the Youth Talent Promotion Project in Shandong, China (Grant No. SDAST2021qt12), and the Natural Science Foundation of Shandong Province, China (Grant Nos. ZR2023QE057, ZR2022QE028, ZR2021QE116, and ZR2020KE027).

Conflict of Interest

The authors declare that they have no conflict of interest.

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