Tribology ( DE G513 )

Case Study Presentation

P. Rajendra Simha(2018H1410125H)
Vipul Agrawal(2018H1410129H)

BITS Pilani
Pilani | Dubai | Goa | Hyderabad
Suman Mondal (2018H1410132H)
Piyush Dhande(2018H1410140H)
 BITS Pilani
Pilani | Dubai | Goa | Hyderabad

Comparing the performance & viability of Nano and

Microfluids in Minimum Quantity Lubrication (MQL) for
machining operations
 Need for the study
• Friction is the major contributor to the temperatures and cutting forces.

• Cutting force increases the power consumption of the machine tool and high cutting
temperatures damage the machined surface. It decreases tool life.

• In this connection, cutting fluids are used as coolants/ lubricants in machining.

• The cutting fluids are highly vulnerable to microbial contamination and lead to skin
diseases in the workers.

• Further, due to their complex ingredients, the fluids need to be treated before disposal.

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 Minimum Quantity Lubrication (MQL)

• MQL is the process of applying minute amounts of high-quality lubricant

directly to the cutting tool/work piece interface instead of using traditional flood
coolants.

• MQL minimizes your environmental impact by significantly reducing fluid

usage and eliminating the need for coolant treatment and disposal. These near-
dry machining benefits are multiplied further when using 100% biodegradable
lubricants which are formulated from renewable plant-based oils.

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 Minimum Quantity Lubrication (MQL)
• MQL uses very small amount of the cutting fluid, less than 500 ml/hr, compared to flood
cooling that uses over 100-120 L/hr.

• Of late, micro/nano particles are dispersed in the cutting fluids to prepare micro/nanofluids
respectively and these fluids are being used in MQL for superior performance.

• In the present work, micro/nano particle suspensions of boric acid (H3BO3) and Molybdenum
disulphide (MoS2) in coconut oil were applied in MQL for machining of AISI 1040 steel on a
lathe at variable cutting conditions.

• H3BO3 and MoS2 have weak Van der waal bonds between individual layers and strong
covalent bonds within a layer. Hence, they can bear higher loads and have lesser coefficient of
friction compared to other solid lubricants.

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 Experimental setup

Schematic of Experimental Setup

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 Experimentation Details

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 Cutting Force

Dry Machining Microfluid Nanofluid

MoS2 Nanofluid 70 % less Cutting Force

H3Bo3 Nanofluid 65 % less Cutting Force

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 MoS2
Similar Structure
H3Bo3

MoS2 Produce strong lubricant layer due to better adsorption properties

H3Bo3 form trioxide in presence of moisture and air

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Course Code – N AME OF THE C O U R SE 10 BITS-Pilani, Hyderabad Campus
 Cutting Temperature
Cutting temperature increases with cutting speed

Dry Machining Microfluid Nanofluid

MoS2 Nanofluids 55 to 65 % lower temperature compared to

dry machining
H3Bo3

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 Results shows better performance of MoS2 Compared to H3Bo3 at both Nano and
micro levels.

At high speeds Nanofluids outperform with respect to Micro fluids

Nanofluids film formed is quicker and stronger than Micro fluid Film

Nanofluids have better heat dissipation properties than micro fluids hence better
cooling at chip tool interface

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 Tool Wear
Important parameter to judge performance of machining process

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 At Low Cutting Speed

10 % lesser wear
MoS2 Microfluid Nanofluid
Compared to

At High Cutting Speed

Difference between Nano and Micro fluids of MoS2 is over 28 %

Nano Boric acid has similar performance as micro MoS2

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 Surface Roughness

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 Nano fluids gave about 40-50 % less surface roughness at all speeds compared to
dry machining

At low Speeds

Nano and Micro Fluids exhibit Similar Performance

At High Speed

Performance of Nano fluid is better with respect to microfluids

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 Economic Analysis
Cutting Fluid Component Considering a flow rate of 10 ml/min for an
average machining time of 6hr/day and five
days a week, the costs for one year will be:
Coconut oil: ₹ 15,500

Cost of Nano particles (0.25% inclusion@ ₹ 8000/50 gm): ₹3,74,000(approx.)

Cost of micro particles (@ ₹ 700/kg) : ₹ 2500 (approx.)

Total cost of A for Nanofluids: ₹ 3,89,500

Total cost of A for micro fluids: ₹ 18,000

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 A 10 HP lathe has been considered for the
Power Consumption Component study and 0.02 HP pump was used to
supply the coolant.

The total costs under the head ‘B’ for a year are:
Power consumption of lathe : ₹ 5,92,000

Power consumption of cutting fluid supply pump: ₹ 520

Hence, B= ₹ 5,92,520

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 Conclusion

1. In all cases of lubrication, performance was better than dry machining.

2. Among the considered solid lubricants, MoS2 gave better performance

compared boric acid.

3. Considering the economy, micro fluids are far economical compared to the
Nanofluids.

4. Microfluids are more viable and are hence adoptable for the machining
industry.

If extreme precision and accuracy are required at high cutting speeds, then
Nanofluids may be a better option.
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 THANK YOU

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