Influence of Al2O3 nanoparticle mass concentration and aerosol formation parameters on tool vibration during turning of Ti6Al4V titanium alloy

Abstract

Machining difficult-to-cut materials involves challenging machining conditions, including higher temperatures in the cutting zone, cutting forces and friction. Another important phenomenon is vibration, which is undesirable when manufacturing high quality workpieces. One way to reduce vibration in the cutting zone is to use cooling methods. Due to its environmentally friendly nature, the minimum quantity lubrication (MQL) method has already been widely used in metalworking. However, when combined with nanofluids, it improves the ability of the aerosol to dissipate more heat and increase lubrication in the cutting zone. This paper presents the effect of a polyol ester-based Al2O3 nanofluid due to the varying mass concentration of nanoparticles on the vibration during turning of Ti6Al4V alloy and compares the results with dry cutting and the MQL method without nanoparticles. Four concentrations (0.25−1 wt%), variable nanofluid flow rate E = 0.388−1.182 g/min and air flow rate P = 10−40 l/min were considered. According to the statistical analysis, the most important factor influencing tool vibration was the mass concentration of nanoparticles in the cutting fluid. By combining the MQL method with 0.5 wt% Al2O3, the vibration acceleration RMS values were found to be the lowest. When compared to the MQL method without nanoparticles, the RMS values for dry cutting ranged from 17.8% to 24.9%, and for wet cutting they were reduced by about 10.9-18.5%.