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Procedia - Social and Behavioral Sciences 195 (2015) 2742 2747

World Conference on Technology, Innovation and Entrepreneurship

Applying Minimum Quantity Lubrication (MQL) Method on

Milling of Martensitic Stainless Steel by Using Nano Mos2
Reinforced Vegetable Cutting Fluid
Alper Uysala *, Furkan Demirena, Erhan Altana
a

<OG]7HFKQLFDO8QLYHUVLW\'HSDUWPHQWRI0HFKDQLFDO(QJLQHHULQJ%HVLNWDV,VWDQEXO7XUNH\

Abstract
Martensitic stainless steel materials have provided some benefits for aerospace, automotive, hydroelectric engines, cutlery,
defense, power hand tools, pump parts, valve seats, chisels, bushings, ball bearings, sporting equipment industry, dental and
surgical instruments etc. due to their hardness, strength, and wear resistance. Machining operations such as milling, turning,
drilling can be applied to give them the final form. But, these kinds of steels are specified as hard-to-machine materials owing to
their high strength, low thermal conductivity and work hardening tendency during machining operations. However, martensitic
stainless steels can be machined by using cutting fluids which are environmentally hazardous, unhealthy, and costly. In this
study, minimum quantity lubrication (MQL) method was applied by using commercial vegetable cutting fluid and 1%wt. of nano
MoS 2 (Molybdenum Disulphide) particles reinforced vegetable cutting fluid during milling of AISI 420 martensitic stainless
steel with uncoated Tungsten Carbide (WC) cutting tool and the sustainable milling operation was performed. The experiments
were carried out at constant cutting speed, feed, and depth of cut. Two different amounts of nanofluids pressure air mist
supplied by MQL system were applied as 20 ml/h and 40 ml/h. In the consequence of milling operations, initial tool wear and
surface roughness were investigated. According to the experimental results, the MQL method reduced the tool wear and surface
roughness. In addition, minimum tool wear and surface roughness values were obtained in nano MQL milling at 40 ml/h MQL
flow rate.
2015 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
2015 The Authors. Published by Elsevier Ltd.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review
under
responsibility
of Istanbul
University.
Peer-review under
responsibility
of Istanbul
Univeristy.
Keywords: MQL; martensitic stainless steel; vegetable nanofluid; tool wear; surface roughness

* Corresponding author. Tel.: +90-212-383-2807; fax: +90-212-383-3024.

E-mail address: auysal@yildiz.edu.tr

1877-0428 2015 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of Istanbul Univeristy.
doi:10.1016/j.sbspro.2015.06.384

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2743

1. Introduction
Stainless steel materials are used in many fields such as power plants, aerospace and automotive industries, dental
and surgical instruments due to their hardness, high temperature properties, high creep rupture strength etc.
However, they are generally known as difficult-to-machine materials because of the work-hardening tendency and
low thermal conductivity. In literature, some researches have been carried out with regard to machining of these
materials. Klim et al. (1996) developed a model considering crater and rake face wear as tool failure criteria to
estimate the reliability of cutting tools under variable and constant feed conditions for 17-4PH stainless steel
material. Lin (1998) investigated the reliability and failure of cutting tools in the face milling of stainless steel
material. Chipping was accepted as tool life criterion and the effect of cutting parameters was examined. Selinder et
al. (1998) evaluated the coated cemented carbide cutting tools in face milling experiments of austenitic stainless
steel. In their study, the multilayered TiN/TaN (Titanium Nitride/Tantalum Nitride) and TiN/NbN (Titanium
Nitride/Niobium Nitride) coated cemented carbide inserts were used. The coating was performed by PVD (Physical
Vapor Deposition) technique. The results indicated that the multilayer coated cutting tools showed superior
performance than single-layer coated cutting tools. Same result was reported in the study of Nordin et al. (2000). Sun
et al. (1998) investigated the interface adhesion behavior between the cutting tool and austenitic stainless steel in
milling operation. According to the experimental results, adhering phenomenon did not occur at high and low cutting
speed, while it was formed at medium cutting speed. El-Hossein and Yahya (2005) performed an experimental study
to investigate the performance of multilayered carbide inserts in end milling of AISI 304 austenitic stainless steels.
Researchers examined the tool wear and the effects of cutting speed and feed rate on tool life. It was found that tool
wear increased with increasing the cutting speed and decreasing the feed rate. Endrino et al. (2006) investigated the
influence of the AlTiN (Aluminum Titanium Nitride) and AlCrN (Aluminum Chromium Nitride) coatings on wear
mechanism and tool life during milling of AISI 316 austenitic stainless steel with carbide end mills. Minimal wear
intensity was observed for cutting tools with the nano-crystalline AlTiN coating. Shao et al. (2007) studied the wear
and failure mechanism of TiCN/TiN (Titanium Carbo-Nitride/Titanium Nitride) multilayer coated cemented carbide
tool during milling process of 3%Co-12%Cr stainless steel. Researchers indicated that the abrasive wear and
adhesion wear were observed in the initial and steady wear stages and diffusion happened in the final wear stage.
Liew and Ding (2008) investigated the wear of uncoated and TiAlN (Titanium Aluminum Nitride) PVD coated
carbide end mills in milling of modified AISI 420 martensitic stainless steel. Researchers presented that the coating
prevented the chipping and enhanced the abrasive wear resistance of the cutting tool. Additionally, it was found that
the failure of the cutting tool could be decreased by using cutting fluid.
In the milling of stainless steels, developing coatings and applying cutting fluids have been studied to increase the
cutting tool life, reduce the cutting tool failure, and to improve the surface finish quality. The developments in the
coating technologies have succeeded these demands but the cutting tool costs have increased. In addition, the cutting
fluids have been also useful but the usage of the cutting fluids has increased the production costs, adversely affected
the health, and created biological and environmental problems. Therefore, MQL (Minimum Quantity Lubrication)
method has been developed. In MQL machining, the coolant is supplied as a mixture of pressure air and cutting fluid
in the form of an aerosol. Besides, EPA (Environmental Protection Agency) has imposed some sanctions on the
applying ample amount of cutting fluid and the use of MQL method has become popular. Rahman et al. (2002) and
Kishawy et al. (2005) compared the MQL method and flood cooling with each other. Researchers indicated that
MQL method could be considered as an alternative to flood cooling because of the reduction in lubricant
consumption. Additionally, de Lacalle et al. (2006) reported that the flood cooling was not effective in high speed
milling due to unable to reach the inner zones of the tool teeth. But, the MQL flow penetrated in the cutting zone and
acted in three different ways as cooling, lubricating, and removing the chips. Liao et al. (2007) performed a
feasibility study on the MQL method in high speed end milling. The experiments were conducted under flood
cooling and dry cutting conditions to compare the results of MQL method. Experimental results showed that the use
of MQL method lead to the best performance and improved the surface finish. Besides, Fratila and Caizar (2011)
presented that the MQL method could be successfully applied without affecting the machining process results such
as surface roughness. Shahrom et al. (2013) investigated the MQL method and flood cooling in milling and

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determined the effect of lubrication conditions on the surface roughness. The MQL method gave better surface
roughness than flood cooling.
According to the performed studies, the MQL method can be an alternative to flood cooling in some milling
operations, especially high speed milling. However, there is a need to develop its performance to machine hard-tocut materials such. For this reason, nanofluids have been produced by adding nanometer sized particles of metals,
oxides, carbides, nitrides, or nanotubes such as carbon nanotube, TiO 2 (Titanium Dioxide), Al 2 O 3 (Aluminum
Oxide), MoS 2 (Molybdenum Disulphide), and diamond to the cutting fluids. These nano additives can enhance the
thermal conductivity and lubrication effect of the cutting fluids and improve the performance of MQL method. Shen
et al. (2008a) investigated the performance of water based Al 2 O 3 and diamond nanofluids in MQL method. It was
found that the nanofluids showed the benefits of reducing forces, improving surface roughness, and preventing
workpiece burning. Shen et al. (2008b) evaluated the effect of nano MoS 2 particles based nanofluid in MQL method.
The results showed that the MQL method with nanofluid application reduced the force and friction. Nam et al.
(2011) studied the effect of nano diamond based nanofluid in the MQL method. The experimental results showed
that the nanofluid MQL significantly increased tool life and reduced the torque and thrust force. Rahmati et al.
(2014) investigated the surface quality and morphology of aluminum alloy in MQL milling with nano MoS 2
reinforced cutting fluid. Researchers presented that the MQL method with nano MoS 2 reinforced cutting fluid could
be an alternative to obtain ideal surface quality.
Previous studies presented that there was not much study about MQL milling of stainless steels, especially MQL
with nanofluid. For this reason, we conducted MQL milling experiments of AISI 420 martensitic stainless steel by
uncoated WC (Tungsten Carbide) cutting tool. It is known that the cutting tools wear relatively high in a short time
at the beginning of the cutting operation and this rapid worn land affects the all process and reduces the tool life. For
this reason, we investigated the effect of cutting condition on reducing the initial tool wear. In addition, the effect of
cutting condition on the surface roughness was examined. In the MQL method, a commercial vegetable cutting fluid
and a nanofluid were used. The nanofluid was prepared by adding nano MoS 2 particles to the vegetable cutting fluid
at weight fraction of 1 to enhance its efficiency. Thus, sustainable and environmentally milling operation could be
performed and hazardous and unhealthy effects of flood cooling could be also eliminated.
2. Experimental Study
In experimental studies, slots were machined on AISI 420 martensitic stainless steel parts by First MCV-300
CNC milling machine. Chemical composition of the stainless steel parts is given in Table 1 and the steel parts were
prepared in the dimensions of 400x250x4 mm.
Table 1. Chemical composition of AISI 420 martensitic stainless steel.
C%

Si%

Mn%

P%

S%

Cr%

0,36

0,42

0,37

0,022

0,003

13,11

In milling operations, SPHN120404 uncoated WC cutting tools were used and mounted on a 32 mm diameter end
mill by mechanically. The milling experiments were conducted at constant spindle speed (995 rpm), feed rate (180
mm/min), and depth of cut (0,5 mm) under dry, MQL with vegetable cutting fluid, and MQL with nanofluid
conditions. Table 2 shows the MQL conditions.
Table 2. MQL conditions.
Milling conditions

MQL flow rate

MQL pressure

Dry
MQL with cutting fluid
MQL with nanofluid

Nozzle angle

Nozzle distance

Nozzle tip diameter

50 mm

1 mm

10
20 ml/h
40 ml/h

5 bar

(in parallel to
the workpiece
surface)

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2745

(1% nano MoS 2 )

In MQL milling, Werte DKN 25 micro lubrication system was used and Eraoil KT/2000 commercial vegetable
cutting fluid was chosen. Nano MoS 2 particles were added to the commercial vegetable cutting fluid at weight
fraction of 1 to obtain the nanofluid. SEM (Scanning Electron Microscopy) image of nano MoS 2 particles can be
seen in Fig. 1. To prepare the nanofluid, nano MoS 2 particles were dried in Termal G11420SD drying oven for 2
hours and then added to the cutting fluid. Additionally, lecitine was added as dispersant to obtain a homogeneous
mixture. The mixture of nano MoS 2 particles and cutting fluid was blended by using Diahan WiseTis HG-15D
digital homogenizer.

Fig. 1. SEM image of nano MoS 2 particles.

Surface roughness (R a ) measurements of milled slots were performed by using Time TR200 surface roughness
tester. The cut-off length was adjusted as 0,8 mm and the resolution of tester is 0,001 m. Five measurements were
done on each surface and arithmetic means were calculated. The tool wears were observed by SOIF XJP-6A
trinocular microscope and the tool wear measurements were performed by utilizing MShot digital imaging system.
3. Results and Discussion
3.1. The Effect of MQL Milling on Tool Wear
At the beginning of the cutting operation, the cutting tools wear quickly and lose a significant part of their life.
For this reason, it is important to reduce the initial tool wear. Fig. 2 shows the effect of cutting condition on the
initial tool wear. Tool wear measurements were performed after milling for 40 seconds. The maximum tool wear
was observed under dry milling. The MQL method decreased the tool wear due to the fact that the pulverized cutting
fluid was able to reach the interface between the cutting tool and workpiece. Besides, the MQL flow rate had
positive effect on the tool wear. Therefore, the tool wear decreased with increase of the pulverized cutting fluid
amount. The tool wear reductions were calculated as 9,8% and 15,5% for the MQL flow rates of 20 ml/h and 40
ml/h, respectively when compared with the dry milling. In addition, the usage of nano MoS 2 particles reinforced
cutting fluid in MQL method gave the minimum tool wear due to the lubrication effect of nano MoS 2 particles. The
pulverized nanofluid reduced the friction between the cutting tool and workpiece and so less tool wears were
observed. The nano MQL method could reduce the tool wear by 16,8% and 19,9% at 20 ml/h and 40 ml/h flow
rates, respectively when compared with the dry milling. The minimum tool wear was obtained in milling with nano
MoS 2 particles reinforced MQL method at 40 ml/h flow rate as seen in Fig. 2.
3.2. The Effect of MQL Milling on Surface Roughness
The MQL method gave better surface roughness than dry milling and the minimum surface roughness was
measured as 0,8644 P in nano MQL milling at 40 ml/h flow rate (Fig. 3). The MQL method decreased the surface

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Alper Uysal et al. / Procedia - Social and Behavioral Sciences 195 (2015) 2742 2747

roughness by 8,8% and 22,5% for the flow rates of 20 ml/h and 40 ml/h, respectively when compared with the dry
milling. In addition, the reductions of the surface roughness were determined as 36,3% and 39,2% at 20 ml/h and 40
ml/ flow rates in nano MQL milling, respectively as compared with the dry milling. According to Fig. 3, the
difference between the surface roughness values measured at 20 ml/h and 40 ml/h flow rates was not too much for
nanofluid because of the fact that the lubrication effect of nano MoS 2 particles had more effective than flow rate in
terms of the surface roughness. However, this difference was much more for pure cutting fluid. Because more
mixture of pressure air and cutting fluid reached to the cutting zone at 40 ml/h flow rate and this caused further
reduction in surface roughness.

Fig. 2. Variation of initial tool wear with cutting condition (milling for 40 seconds).

Fig. 3. Variation of surface roughness with cutting condition.

4. Conclusion
In this study, the effect of cutting conditions on the initial tool wear and surface roughness was investigated in
milling of AISI 420 martensitic stainless steel. The experiments were conducted under dry, MQL with vegetable
cutting fluid, and MQL with nanofluid. Nano MoS 2 particles were added to the vegetable cutting fluid at weight

Alper Uysal et al. / Procedia - Social and Behavioral Sciences 195 (2015) 2742 2747

2747

fraction of 1 to prepare the nanofluid. Experimental results showed that the MQL method could decrease the tool
wear and surface roughness. Besides, an increment of the MQL flow rate caused a reduction in both the tool wear
and surface roughness. Additionally, the use of nano MoS 2 particles reinforced cutting fluid in MQL milling gave
the minimum tool wear and surface roughness due to the lubrication effect of nano MoS 2 particles.
Acknowledgments
This research has been supported by 7KH6FLHQWLILFDQG7HFKQRORJLFDO5HVHDUFK&RXQFLORI7XUNH\7h%7$.
Project Number: 114M098.
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