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A note on the use of the minimum quantity

lubrication (MQL) system in turning


Diego Carou
Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal

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

conventional cooling, highlighting cooling by flooding, mist


cooling and high pressure systems (Avallone and Baumeister,
1996; Courbon et al., 2009).
However, there are also some disadvantages associated to
the use of the cutting fluids such as their costs, environmental
impact and safety (Klocke and Eisenbltter, 1997; Kurgin
et al., 2012). These drawbacks encourage the research on the
development of new cutting fluids such as the bio-based
cutting fluids (Ozcelik et al., 2011) and new
cooling/lubricating alternatives. Among them, dry machining
is one of the most promising, representing the ultimate goal to
achieve machining processes environmentally friendly.
Nevertheless, dry machining processes need to give
comparable results as conventional cooling processes, in terms
of operation time, tool life and surface quality.
The absence of cutting fluids in machining has as main
disadvantages the appearance of adhesion mechanisms, heat
generation, increase in friction between tool and workpiece
and poor chip evacuation. However, dry machining offers as

Traditionally, cutting fluids have been used in machining to


reduce the friction and the temperature reached in the process
(Nouari, 2003). The cutting fluids used in machining can be
classified into two main groups: neat cutting oils and
water-soluble fluids (El Baradie, 1996).
The use of cutting fluids can also provide additional
advantages such as:

the removal of the chips from the tool rake face;

the limitation of chemical diffusion;

diminishing tool wear;

diminishing power consumption; and

the protection of the machined surfaces from corrosion


(Nouari, 2003; Avallone and Baumeister, 1996).
However, the performance of the cutting fluids is conditioned
by several issues such as the type of operation, cutting
conditions and workpiece material (De Chiffre and Belluco,
2000). In addition, several application methods can be used in

The current issue and full text archive of this journal is available on
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The authors thank to the Research Group of the UNED Mechanical,


Materials and Manufacturing Technologies (TM3) the given support
during the development of this work, and funding of the Spanish Ministry
of Science and Innovation (Project DPI2011-27135) and of the Industrial
Engineering School-UNED (Project REF2014-ICF05) to carry it out.

Industrial Lubrication and Tribology


67/3 (2015) 256 261
Emerald Group Publishing Limited [ISSN 0036-8792]
[DOI 10.1108/ILT-07-2014-0070]

Received 31 July 2014


Revised 31 July 2014
Accepted 1 September 2014

256

Minimum quantity lubrication (MQL) system in turning

Industrial Lubrication and Tribology

Diego Carou, Eva M. Rubio and J. Paulo Davim

Volume 67 Number 3 2015 256 261

2. Minimum quantity lubrication

an advantage the absence of thermal shocks (Klocke and


Eisenbltter, 1997).
Despite the technological development produced in recent
years, dry machining is not an adequate technique for all the
processes needed in the industry (Kelly and Cotterell, 2002).
In this sense, Weinert et al. (2004) analyses several cutting
operations using as material workpiece: aluminium, cast iron
and steel. Some of these cutting operations can be done using
dry machining, but there are other operations (drilling,
reaming, sawing, taping or thread forming) in which, at least,
the use of the minimum quantity lubrication (MQL) system is
recommended. Fratila (2013) states that the workpiece
materials used in the aerospace industry (nickel alloys,
titanium alloys, Co-Cr alloys), in combination with the high
cutting speeds required, make difficult the use of the dry
machining. In the case of drilling, Filipovic and Stephenson
(2006) state that drilling without coolants can produce
excessive thermal distortion and poor tool life. For instance,
because of the adhesion of chips to the tool, dry machining is
not recommended in drilling of Al-Si alloys (Dhar et al.,
2006).
There are several processes in which it is not possible to
suppress the cutting fluids. Therefore, machining must be
done using conventional cooling or other alternatives. In this
sense, alternatives such as solid lubricants (Shaji and
Radhakrishnan, 2003), gaseous refrigeration (akr et al.,
2004), cryogenic refrigeration (Yildiz and Nalbant, 2008) or
MQL system can be used (Figure 1).
The present work is focussed on the study of one of the
aforementioned alternatives: the MQL system. The study is
divided in two sections. The first one shows a general
approximation to the MQL system, and the second one
provides a revision of some of the main experimental research
on this alternative. Although the use of the MQL system has
been evaluated in the turning of different kind of materials
such as metal matrix composites (MMCs) (Davim et al.,
2009) or brasses (Davim et al., 2007; Gaitonde et al., 2008), in
the present work, the review only covers nickel-base alloys,
steels and light metals: titanium alloys, aluminium alloys and
magnesium alloys.

MQL, also known as near dry machining (NDM), is an


alternative to conventional cooling. MQL systems reduce
drastically the cutting fluid consumption, using up to 10,000
times lower volumes of fluids, mixed with air, than in
conventional cooling (Weinert et al., 2004; Sharma et al.,
2009).
The use of the MQL system as an alternative method to wet
machining has to consider the special characteristics of the
method. In this sense, it is interesting to contrast the
properties of the method against the objective and traditional
methods: dry and wet machining. In Figure 2, it is possible to
see this comparison, focussing on characteristics of great
importance such as the cooling and lubricating effect or the
chip transport (Grzesik, 2008).
The main application method used in the MQL system is
the use of compressed air plus a cutting fluid flow (Figure 3),
being mist generation the main disadvantage of this method,
which pose a health hazard to operators (Ezugwu, 2005). The
selection of the cutting fluids cannot be done based on their
primary properties (refrigeration, lubrication and chip
evacuation). Thus, their secondary properties: biodegradability,
oxidation stability and storage stability must be also considered
(Weinert et al., 2004). Secondary properties were studied by
Wakabayashi et al.s (2006) finding that some synthetic polyol
esters exhibit high biodegradability, excellent oxidation stability
and satisfactory cutting performance.
A wide range of parameters, such as type of cutting fluid,
nozzle configuration, volume rate or pressure, can be selected
in the MQL systems. Therefore, the prediction of the results is
not easy. To solve this problem, Marksberry and Jawahir
(2008) developed a model, derived from Jawahirs tool wear
prediction under dry machining, including both cutting
parameters and cooling system, to predict the results when
using MQL systems [equation (1)]:

km
vR

T TR n1
n2
v
f d

nc

NNDM

(1)

Figure 2 Comparative properties of dry machining, flood cooling


and MQL system (Grzesik, 2008)

Figure 1 Main cooling/lubricating systems

257

Minimum quantity lubrication (MQL) system in turning

Industrial Lubrication and Tribology

Diego Carou, Eva M. Rubio and J. Paulo Davim

Volume 67 Number 3 2015 256 261

Figure 3 Scheme of the MQL system

use of the MQL system allows to obtain better values than


those obtained when machining with wet conditions.
Kamata and Obikawa (2007) also analysed the high-speed
grooving of Inconel 718, testing three types of coatings:
1 A chemical vapour deposition (CVD) three-layer coating
of TiCN/Al2O3/TiN.
2 A physical vapour deposition (PVD) superlattice coating
of TiN/AlN.
3 A PVD monolayer coating of TiAlN.

Where the factors represent:


T
Tool life.
Reference tool life for 1 min.
TR
K, n1, n2 Empirical constants.
M
Constant depending on the manufacturing
process.
F
Feed rate.
D
Depth of cut.
VR
Reference cutting speed for 1 min of tool life.
V
Cutting speed.
Nc
Coating effect factor.
NNDM Contribution of the cooling system in the process.

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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Minimum quantity lubrication (MQL) system in turning

Industrial Lubrication and Tribology

Diego Carou, Eva M. Rubio and J. Paulo Davim

Volume 67 Number 3 2015 256 261

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.

values of tool life are obtained at the lower cutting speeds,


reaching a maximum value of 7.4 min. However, at the higher
cutting speed the maximum value only reaches 4.5 min.
Wang et al. (2009) also studied the turning of titanium
alloys. Concretely, authors researched the orthogonal turning
of Ti6Al4V alloy, comparing dry machining and wet
machining to the MQL system, using a vegetable oil during
continuous and interrupted cutting. In continuous cutting,
when machining at high cutting speed and feed rate, the MQL
system seems to be more effective than wet machining because
of its better lubrication ability. The same is highlighted in the
case of interrupted cutting, considering that the use of the
MQL system is more effective than the use of dry machining
and wet machining.
3.3.2 Aluminium alloys
Sreejith (2008) analysed the turning process of 6061
aluminium alloy using the MQL system. The results of the
study recognise that the MQL system can produce results
comparable with that of wet machining conditions.
Itoigawa et al. (2007) studied the intermittent turning of
A6063-T5 aluminium alloy, testing two types of cutting fluids:
1 Paraffinic mineral oil without additives.
2 Refined vegetable oil that are supplied to the cutting zone
using an MQL system with a flow rate of 10 ml/h.
The results of the work suggest that the lubrication
mechanism of the MQL aluminium cutting considerably
changes, depending on the lubricant types and the
temperature on the tool face.
3.3.3 Magnesium alloys
Magnesium alloys are increasing their use in several industrial
sectors like the aerospace and automotive (Pu et al., 2012).
The application of the MQL system is analysed by Rubio et al.
(2014) in the intermittent turning of UNS M11917
magnesium alloy. The work studies repair and maintenance
operations, finding that, within the range analysed, there is an
optimum MQL flow rate that leads to a moderate
improvement in the surface roughness, based on statistical
analysis. Concretely, the optimum value for the MQL flow
rate was identified in 4.5 ml/h (Table I).

3.3 Light alloys


3.3.1 Titanium alloys
Settireni and Faga (2008) studied the turning process of TA48
titanium alloy, testing cutting speeds of 50, 90 and 130 m/min.
The use of the MQL system shows higher average tool life than
when using wet machining for several types of tools: WC-Co and
AlSiTiN- and TiCN-coated tools. In the MQL case, higher

Table I Main characteristics of the MQL systems used in reviewed turning processes
Authors

Material

MQL conditions

Obikawa et al. (2008)


Kamata and Obikawa (2007)
Stephenson et al. (2014)
Diniz et al. (2003)
Dhar et al. (2006)
Varadarajan et al. (2002)
Attanasio et al. (2006)
Bruni et al. (2006)
Settireni and Faga (2008)
Wang et al. (2009)
Sreejith (2008)
Itoigawa et al. (2007)

Inconel 718
Inconel 718
Inconel 750
AISI 52100
AISI 4340
AISI 4340
100Cr6
AISI 420B
TA48
Ti6Al4V
6061
A6063-T5

Rubio et al. (2014)

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

259

Minimum quantity lubrication (MQL) system in turning

Industrial Lubrication and Tribology

Diego Carou, Eva M. Rubio and J. Paulo Davim

Volume 67 Number 3 2015 256 261

4. Conclusions

Machine Tools and Manufacture, Vol. 49 No. 14,


pp. 1114-1125.
Davim, J.P., Sreejith, P.S. and Silva, J. (2007), Turning of
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Davim, J.P., Sreejith, P.S. and Silva, J. (2009), Some studies
about machining of MMC=S by MQL (Minimum Quantity
of Lubricant) conditions, Advanced Composites Letters,
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Effect of minimum quantity lubrication (MQL) on tool
wear and surface roughness in turning AISI-4340 steel,
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pp. 299-304.
Diniz, A.E., Ferreira, J.R. and Filho, F.T. (2003), Influence
of refrigeration/lubrication condition on SAE 52100
hardened steel turning at several cutting speeds,
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El Baradie, M.A. (1996), Cutting fluids: part I.
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Ezugwu, E.O. (2005), Key improvements in the machining
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Filipovic, A. and Stephenson, D.A. (2006), Minimum
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Fratila, D. (2013), Sustainable manufacturing through
environmentally-friendly machining, in Davim, J.P. (Ed.),
Green Manufacturing Processes and Systems, Springer,
Heidelberg, pp. 1-21.
Gaitonde, V.N., Karnik, S.R. and Davim, J.P. (2008),
Selection of optimal MQL and cutting conditions for
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Materials Processing Technology, Vol. 204 Nos 1/3,
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Materials, Elsevier, Amsterdam, pp. 226-245, pp. IX-XI.
Itoigawa, F., Takeuchi, D., Nakamura, T. and
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Machining Science and Technology, Vol. 11 No. 3,
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machining of aluminium alloys, Journal of Materials
Processing Technology, Vol. 120 Nos 1/3, pp. 327-334.

In the past decades, both industry and researchers have


focussed their attention in the search for alternatives to the use
of conventional cutting fluids in machining processes, mainly
due to the high costs and environmental impact of the cutting
fluids. In this sense, several alternatives have been developed
such as, to name a few, cryogenic refrigeration or solid
lubricants. Of special interest is the case of the MQL system,
taking into account that in some machining processes avoiding
the use of cutting fluids cannot be done without reducing the
quality of the machined pieces and/or the productivity of the
process.
The use of the MQL system maintains the main philosophy
and objectives of wet machining (reduction of friction,
removal of chips, reduction of temperature, etc.), but
establishing as strategy the reduction of the quantity of cutting
fluid consumed. Thus, the flow rates used in the MQL system
are usually up to 10,000 times lower than that of the used in
wet machining.
The present work provides an approximation to the MQL
system in Sections 1 and 2, explaining the main characteristics
of the cooling/lubricating system. In addition, Section 3
provides a revision of some of the main experimental works on
the use of the MQL system. The section is divided in
sub-sections based on the workpiece material use in the
studies. Thus, works were classified in: nickel-base alloys,
steels and light metals, including aluminium alloys,
magnesium alloys and titanium alloys.
The revision of research studies let acknowledge how the
use of the MQL system can help to improve the results of the
turning process, for instance, in terms of tool life or surface
roughness when comparing with the use of dry or wet
machining. However, as it was identified, in some cases, the
use of the MQL system does not provide better results than
those obtained with other systems. Thus, the use of the MQL
system must be conveniently assessed for each specific
process.

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Minimum quantity lubrication (MQL) system in turning

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Diego Carou, Eva M. Rubio and J. Paulo Davim

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About the authors


Diego Carou received his PhD degree in Industrial
Engineering from the National University of Distance
Education (UNED) in 2013. In 2013-2014, he continued his
research as Postdoc at the Department of Mechanical
Engineering of the University of Aveiro. Diego Carou is the
corresponding author and can be contacted at:
diecapor@gmail.com
Eva M. Rubio received the MSc degree in Aeronautical
Engineering in 1997 from the Technical University of Madrid
(UPM) and the PhD degree in 2002 from the National
University of Distance Education (UNED). She works as
Associate Professor at the Manufacturing Engineering
Department (UNED) where she coordinates the Master of
Manufacturing Advanced Engineering and participates in the
Master of Research in Industrial Technologies and in the
Master of Science and Technology of Polymers, UNED.
J. Paulo Davim received his PhD degree in Mechanical
Engineering from the University of Porto in 1997 and the
Aggregate title from the University of Coimbra in 2005.
Currently, he is Professor at the Department of Mechanical
Engineering of the University of Aveiro.

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