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Research Papers: Lubricants

Effect of Nano-Enhanced Lubricant in Minimum Quantity Lubrication Balling Milling

[+] Author and Article Information
Kyung-Hee Park, Brent Ewald

 Manufacturing System R&D Department, Korea Institute of Industrial Technology, 35-3 Hongcheon-ri, Ipjang-myeon, Cheonan-si, Chungcheongnam-do, 330-825, Republic of Korea e-mail: kpark@kitech.re.kr Department of Mechanical Engineering, Michigan State University, East Lansing, MI 48824 e-mail: ewaldbr2@msu.edu

Patrick Y. Kwon1

 Department of Mechanical Engineering, Michigan State University, East Lansing, MI 48824 e-mail: pkwon@egr.msu.edu

1

Corresponding author.

J. Tribol 133(3), 031803 (Jul 28, 2011) (8 pages) doi:10.1115/1.4004339 History: Received September 20, 2010; Revised June 06, 2011; Published July 28, 2011; Online July 28, 2011

Minimum quantity lubrication (MQL) has been used as an alternative solution for flood cooling as well as dry machining. However, the benefit of MQL is only realized in mild machining conditions as the heat generation during more aggressive machining conditions cannot be effectively eliminated by the small amount of oil mist being applied during MQL process. To extend the applicability of MQL to more aggressive machining conditions, we have developed a potential additive to MQL lubricant. After the preliminary wetting angle measurement of the various lubricants, one commercially available MQL vegetable oil was chosen, which is then mixed in a high-speed mixer with exfoliated nanographene particles. The resulting nanoenhanced MQL lubricant was evaluated for its tribological and machining behaviors together with the suspension stability of the mixture. Friction coefficients of new nanoenhanced MQL oil were also measured in terms of loads, speeds and lubricants. Finally, MQL-ball milling tests with nanographene enhanced lubricant were performed to show a remarkable performance improvement in reducing both central wear and flank wear as well as edge chipping at cutting edge.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Images of exfoliated graphite nanoplatelet (xGnP)

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Figure 2

Suspension stability of xGnP oils ((a) 1 μm/0.1 wt %, (b) 1 μm/1.0 wt %, (c) 15 μm/0.1 wt %, (d) 15 μm/1.0 wt %) in 3 days after mixing

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Figure 3

Wetting angle of a droplet

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Figure 4

Wetting angle measurement setup

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Figure 5

Tribometer setup

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Figure 6

MQL and ball milling setup

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Figure 7

Tool wear measurements of a ball nose insert

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Figure 8

Wetting angle test results (left angle, right angle)

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Figure 9

Friction coefficient at various test conditions

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Figure 10

Comparison of friction coefficients of dry and xGnP coating at 5 N and 2.5 cm/s

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Figure 11

Comparison of friction coefficients of lubricants at 10 N and 2.5 cm/s

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Figure 12

Central wear at 3500 rpm after eighth pass

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Figure 13

Flank wear at 4500 rpm after eighth pass

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Figure 14

Central wear and flank wear in terms of concentration of xGnP

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