An Experimental Study on Ultrasonic Vibration-Assisted Turning of Aluminum Alloy 6061 with Vegetable Oil-Based Nanofluid Minimum Quantity Lubrication

Abstract

Minimum quantity lubrication (MQL) is a potential technology for reducing the consumption of cutting fluids in machining processes. However, there is a need for further improvement in its lubrication and cooling properties. Nanofluid MQL (NMQL) and ultrasonic vibration-assisted machining are both effective methods of enhancing MQL. To achieve an optimal result, this work presents a new method of combining nanofluid MQL with ultrasonic vibration assistance in a turning process. Comparative experimental studies were conducted for two types of turning processes of aluminum alloy 6061, including conventional turning (CT) and ultrasonic vibration-assisted turning (UVAT). For each turning process, five types of lubricating methods were applied, including dry, MQL, nanofluid MQL with graphene nanosheets (GN-MQL), nanofluid MQL with diamond nanoparticles (DN-MQL), and nanofluid MQL with a diamond/graphene hybrid (GN+DN-MQL). A specific cutting energy and areal surface roughness were adopted to evaluate the machinability. The results show that the new method can further improve the machining performance by reducing the specific cutting energy and areal surface roughness, compared with the NMQL turning process and UVAT process. The diamond nanoparticles are easy to embed on the workpiece surface under the UVAT process, which can increase the specific cutting energy and Sa as compared to the MQL method. The graphene nanosheets can produce the interlayer shear effect and be squeezed into the workpiece, thus reducing the specific cutting energy. The results provide a new way for the development of eco-friendly machining.