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Eva M. Rubio
Department of Manufacturing Engineering, National University of Distance Education (UNED), Madrid, Spain, and
J. Paulo Davim
Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal
Abstract
Purpose The purpose of this paper is to provide a practical review of the use of the minimum quantity lubrication (MQL) system in turning
operations, focussing on the application of the technique in the turning of different kind of materials.
Design/methodology/approach The use of the MQL system was analysed by several researchers in the past years. Thus, in the present paper,
a relevant sample of the main experimental studies that can be found in the literature was analysed to come up with a review with relevant
information for researchers and industry.
Findings The use of the MQL system can help to improve the outcomes of the turning process in several issues like surface quality or tool life.
However, it was also recognised that in some cases, other cooling/lubricating methods can provide better results than the MQL system. Thus, the
decision, whether to use or not the MQL system in a specific process, is of great importance.
Originality/value The work is conveniently focussed to serve as a quick reference on the issue. At the same time, the work analysed the use of
the turning of some of the main engineering materials that makes it useful for a wider range of researchers and metalworking firms. Finally, the
review could be useful to improve the performance of the industry, especially for the metalworking firms in terms of costs, environmental impact
and safety.
Keywords Cutting fluids, Light alloys, Minimum quantity lubrication, Nickel-base alloys, Steels, Turning
Paper type General review
1. Introduction
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In their work, authors show that the MQL system can offer
tool life longer than when using dry machining conditions, and
even better than when using conventional cooling for two of
the three coatings analysed.
Analysing the surface roughness, the MQL systems improve
the results obtained with conventional cooling and dry
machining (Kamata and Obikawa, 2007).
From another side, Stephenson et al. (2014) studied the rough
turning process of Inconel 750. In their tests, authors compared the
performance of aqueous flood and CO2 MQL. The results show
how the CO2 MQL system can provide better tool life results than
aqueous flood coolant in rough turning of Inconel 750.
3. Experimental research
3.1 Nickel-base alloys
The use of the MQL system in nickel-base alloys turning can
be a good alternative to wet machining. In particular, it can
improve the tool life or tool wear. In this sense, the work by
Obikawa et al. (2008) proves how, even using very small
amounts of cutting fluid, the use of especially designed nozzles
can lead to benefits in tool life when the oil mist is
conveniently applied to the cutting zone in the turning of
Inconel 718. Flow rates used in the research were from 0.2 to
15 ml/h, obtaining better tool life when using the MQL system
than when using dry machining, but poorer results than those
obtained when using conventional cooling. In addition, when
using a cover-type nozzle, the results of the MQL system are
closer to those obtained under wet machining. The surface
roughness measured at the end of the tool life shows how the
3.2 Steels
The field of steels has a wide set of experimental investigations on
the use of the MQL system. For instance, the one provided by
Diniz et al. (2003) in the hard turning of AISI 52,100 steel, with
polycrystalline cubic boron nitride tools and a cutting speed of
110 m/min. In their study, authors evaluate the results in terms of
flank wear when using dry and wet machining, compressed air
and the MQL system, using 10, 30 and 60 ml/h, respectively.
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Close values of flank wear were obtained for dry machining and
the MQL system; these results being better than the ones
obtained with wet machining. Regarding the surface roughness,
the MQL system and dry machining offered close values, and
even better than the ones obtained with the conventional cooling.
Another experimental work on steels is the one provided by
Dhar et al. (2006). Authors studied the turning process of
AISI 4,340 steel, finding that the use of the MQL system
provided reduced tool wear, improved tool life and better
surface finish as compared to dry and wet machining.
Varadarajan et al. (2002) researched the use of the MQL
system, using a mineral oil as cutting fluid, in the turning
process of AISI 4,340 steel. In the experimental tests, it was
identified a better performance of the MQL system than that
of the dry machining and wet machining on the basis of
cutting force, tool life, surface finish, cutting ratio, cutting
temperature and tool-chip contact length.
The effect on the tool wear of the MQL system is evaluated in
the work by Attanasio et al. (2006) in the turning of 100Cr6 steel.
Two different supply methods were tested to compare their
results to the ones obtained when using dry machining.
Concretely, flank and rake MQL methods were tested. The
results show how a beneficial effect of the MQL system appears
when supplying the cutting fluid to the flank, whereas when
choosing the rake, no reduction in tool wear was observed.
The finish turning process of AISI 420B was studied by Bruni
et al. (2006), testing dry and wet machining, and the MQL
system. The main results of the research include the recognition
that the lubrication-cooling technique does not significantly
affect the tool wear, whilst the use of wet machining produces the
highest surface roughness, and that the use of the MQL
technique does not provide advantages in comparison to dry
cutting in terms of tool life and surface roughness.
Table I Main characteristics of the MQL systems used in reviewed turning processes
Authors
Material
MQL conditions
Inconel 718
Inconel 718
Inconel 750
AISI 52100
AISI 4340
AISI 4340
100Cr6
AISI 420B
TA48
Ti6Al4V
6061
A6063-T5
UNS M11917
Flow rate: 0.2-15 ml/h/Pressure: 0.4 MPa Ester and compressed air
Flow rate: 16.8 ml/h/Pressure: 0.4-0.6 MPa biodegradable synthetic ester
Flow rate: 10-20 ml/h/Pressure: 16.5 MPa soybean oil
Flow rate: 10, 30 and 60 ml/h/Pressure: 0.45 MPa
Flow rate: 60 ml/h/Pressure: 0.7 MPa
Flow rate: 0.033 ml/h/Pressure: 0.4 MPa commercial mineral oil
Flow rate: 20 mg/h/Pressure: 0.25 MPa ester oil with EP additive
Flow rate: 10 ml/h vegetable-based cutting oil
Vegetable oil
Vegetable oil
Flow rate: 50 and 100 ml/h commercial oil
Paraffinic mineral oil without additives and refined vegetable oil, which mainly consists of
a triol-ester with large polarity Flow rate: 10 ml/h
Flow rate: 4.5 and 9 ml/h
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4. Conclusions
References
Attanasio, A., Gelfi, M., Giardini, C. and Remino, C. (2006),
Minimal quantity lubrication in turning: effect on tool
wear, Wear, Vol. 260 No. 3, pp. 333-338.
Avallone, E.A. and Baumeister, T. (1996), Marks Standard
Handbook for Mechanical Engineers, 10th ed., McGraw Hill,
New York, NY.
Bruni, C., Forcellese, A., Gabrielli, F. and Simoncini, M.
(2006), Effect of the lubrication-cooling technique, insert
technology and machine bed material on the workpart
surface finish and tool wear in finish turning of AISI 420B,
International Journal of Machine Tools and Manufacture,
Vol. 46 Nos 12/13, pp. 1547-1554.
akr, O., Kiyak, M. and Altan, E. (2004), Comparison of
gases applications to wet and dry cuttings in turning,
Journal of Materials Processing Technology, Vols 153/154,
pp. 35-41.
Courbon, C., Kramar, D., Krajnik, P., Pusavec, F., Rech, J.
and Kopac, J. (2009), Investigation of machining
performance in high-pressure jet assisted turning of Inconel
718: An experimental study, International Journal of
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