Int J Adv Manuf Technol
DOI 10.1007/s00170-015-8256-y
ORIGINAL ARTICLE
Experimental investigation of flank wear in end milling
of aluminum alloy with water-based TiO2 nanofluid lubricant
in minimum quantity lubrication technique
M. S. Najiha 1 & M. M. Rahman 1,2
Received: 9 July 2015 / Accepted: 16 December 2015
# Springer-Verlag London 2016
Abstract This paper investigates the minimum quantity lu-
brication technique in end milling of aluminum alloy AA6061
with minimum quantity lubrication (MQL) conditions using
nanofluid. Wear mechanisms for the water-based TiO 2
nanofluid with a nanoparticle volume fraction of 1.5 % are
compared with conventional oil-based minimum quantity lu-
brication (0.48 and 0.83 ml/min) and flooded cooling condi-
tions using an uncoated tungsten carbide insert. Wear mecha-
nisms are characterized. Results show adhesion of the work
material as the major tool damage phenomenon. Abrasion
wear is also observed along with adhesion. The major benefit
from the water-based nanofluid MQL is shown in the intact
edge geometry, i.e., edge integrity showing very little chipping
as well as edge fracture. This is attributed to the cooling effect
produced by the latent heat of vaporization of water, resulting
in lowering of temperature in the cutting zone.
Keywords MQL . Nanofluid . Wear . Abrasion . Attrition .
Adhesion
1 Introduction
Given the state-of-the-art technology, the major manufactur-
ing activity is machining that involves many factors having
* M. S. Najiha
mustafizur@ump.edu.my
1
Automotive Engineering Research Group, Faculty of Mechanical
Engineering, Universiti Malaysia Pahang, 26600 Pekan, Pahang,
Malaysia
2
Automotive Engineering Centre, Universiti Malaysia Pahang,
26600 Pekan, Pahang, Malaysia
potential for sustainable development. Minimum quantity lu-
brication (MQL) is a manufacturing approach where very
minimal amounts of the fluids coupled with a meager amount
of airborne cutting mist on factory shop floors [1] are used.
However, to achieve high cooling ability with MQL, a fluid
with high thermal conductivity must be selected. Cooling is
one of the most important challenges in the machining process
[2]. The conventional methods of enhancing the cooling rate
have already been exhausted to their limits [3–6]. Keeping in
view the above-mentioned challenges presented in machining
processes, use of new and innovative cutting fluids is highly
desirable in order to achieve high-performance cooling. Uti-
lizing nanocutting fluid or the nanofluids as cooling/
lubricating media in machining is one of the novel ap-
proaches. Nanofluids are the new generation of potential heat
transfer fluids with enhanced thermo-physical properties and
heat transfer performance. According to the data presented in
recent research, it has been identified that nanofluids can be a
promising substitute for conventional metal working fluids
accompanied with MQL techniques. The applicability of
nanofluids as coolants is mainly because of the enhanced ther-
mal conductivity of the fluids due to solid particle inclusions
[7] and the convection heat transfer coefficient of the fluid can
be largely enhanced by suspended nanoparticles [8].
Nanocoolants can be delivered into the cutting zone in a ma-
chining process through nozzles like flood cooling systems
but the higher fabrication costs of nanofluid and large losses
during application [9] have led researchers to explore the
higher potentials of nanofluids integrated with the principles
of MQL.
Improved machinability in terms of better surface quality
of the bearing steel with mixed ceramic tools with MoS2 and
graphite has been reported [10]. Nanoparticle inclusion was
found to be beneficial in improving the coolant properties in
terms of enhanced thermal conductivity and improved heat

transfer coefficients up to an inclusion fraction of 6 % of
nanoparticles in turning [11]. The use of carbon nanotubes
has shown an improvement in the surface characteristics of
AISI D2 tool steel in the grinding process from a micro level
to a nano level [12]. A series of nanofluid MQL mesoscale
grinding experiments were carried out with nanodiamond par-
ticles and paraffin oil as the base fluid and significantly favor-
able results in terms of reduced grinding forces and surface
roughness were obtained when compared with dry and pure
MQL cases [13]. In addition, it was reported that smaller
nanodiamond particles could be more beneficial to the pro-
duction of better ground surfaces. A nanodiamond volumetric
concentration of 1 % in the case of the paraffin oil and 2 % in
the case of vegetable oil proved to be most effective for re-
ductions in drilling torques and thrust forces [14]. Cooling
capabilities of cutting fluids in terms of reduced nodal tem-
peratures were assessed using carbon nanotube (CNT) con-
tent. It was shown that the change in nodal temperature is less
beyond 2 % CNT inclusion, corresponding to the change in
thermal conductivity [7]. Nanographene-enhanced vegetable
oil fluid provides better results in terms of wettability and a
reduced friction coefficient in MQL. Better performance is
achieved in terms of tool wear and edge chipping [15]. Re-
duced cutting temperatures and better performance in terms of
tool flank wear and surface roughness are obtained while
using nanoboric acid inclusion in the coconut oil [16]. Im-
provement is based on the increased thermal conductivity
and enhanced heat transfer coefficient. The use of water-
based Al2O3 and diamond nanofluids shows a reduction in
grinding force, improvement in surface roughness, and an
improved G ratio with high concentrations of nanofluids in
the MQL grinding process [17]. The tribological properties
and application performance of water-based TiO2 nanofluid
were investigated in the MSR 10D four ball tribotester and in
bench drilling operations and it was found that surface-
modified TiO2 nanoparticles could effectively reduce the load
carrying capacity, as well as friction-reducing and anti-wear
properties of pure water [18]. A lot of research has been re-
ported in the literature about the use of nanoparticles as addi-
tives to traditional oil-based lubricants and all the results of
these researches show that nanoparticle inclusions in oil-based
fluid show improved performance in terms of reduced wear
and decreased friction. Research on the application of nano-
particles as a water-based cooling/lubricating medium is very
rare [18]. The use of water-based nanofluid for machining
increases the sustainability of the process regarding the non-
biodegradability and toxicity of the oils.
The present study aims to assess the performance of
nanofluid as lubricant as well as to characterize the wear
mechanisms of MQL machining using water-based TiO2
nanofluid. The wear mechanisms of the tool with the TiO2
nanoparticles in water are characterized and discussed using
SEM and EDX analysis.
Int J Adv Manuf Technol
2 Selection of three nozzles for mql application
Prior to experiments, a three-dimensional computational fluid
dynamics (CFD) analysis of minimum quantity lubricant flow
for a four-tooth milling cutter operation with single and three
nozzles was carried out [19]. The CFD analysis of the arrange-
ment of the nozzles around the tool periphery is performed in
order to study the effect of the MQL jet and number of nozzles
on the lubrication region. The domain of a rotating cutter
along with the spraying nozzle was defined. A steady-state,
pressure-based, planar analysis was performed with a viscous,
realizable k-ε model for a single-nozzle analysis. A 3-D tran-
sient-case, incompressible analysis for the minimum quantity
lubricant is also performed. The diameter of the nozzle is
considered to be 2 mm. In the case of 3-D analysis, the nozzle
is placed at 45 ° to the tool axis of rotation and at a height of
15 mm and 15 mm from the cutter–workpiece interface. The
domain of the milling cutter is rotated at a spindle speed of
2000 rpm, and a single-nozzle is used to investigate the effects
of MQL spray. A two-dimensional steady-state analysis is also
carried out using CFD with three nozzles placed at 120 ° to
each other. The cutting medium is assumed to be a mixture of
compressed air and oil. It is observed from the single-nozzle
analysis that the fluid flow rate has to be increased in order to
ensure that the fluid penetrates into the cutting zone. The
problem of incomplete lubrication, i.e., uneven distribution
of the fluid along the periphery of the tool, can be solved by
using more than the single nozzle. The nozzle position in
relation to feed direction is very important in order to obtain
the optimum effect of the MQL flow. Another analysis is
performed with three nozzles placed at equal angles to each
other around the periphery of the tool. The nozzle position in
relation to feed direction is very important in order to obtain
the optimum effect of the MQL flow. In the case of 3-D anal-
ysis, the position of the nozzle (nozzle height and axial dis-
tance) produces some improvement in the distribution of the
fluid compared to the results obtained from the 2-D analysis.
The three nozzles may work well for the complete lubrication
of the rotating tool. Hence, it can be concluded that the most
effective MQL nozzle performance is with the three-nozzle
arrangement while keeping the mass flow rate constant.
Figure 1a shows the velocity contour for the tool with MQL
jet in the case of three-dimensional single-nozzle analysis. The
velocity vector plot for the MQL jet shows that the spray does
not cover the periphery of the tool. The cutting surface is not
entirely lubricated. The flow is scattered because of the high
vortex created by the high speed of the cutter. The flow strikes
the cutter but splashes back because of the turbulence.
Figure 1b shows the velocity contour of the flow field of the
MQL jet in the case of the three-nozzle analysis. The flow
field shows that spray from the three nozzles, equidistant from
each other, covers the periphery of the tool. A turbulence
region is created around the rotating tool as it is rotating at a
Int J Adv Manuf Technol

4.06e+02 used for nanofluid-MQL machining. The water-based

3.86e+02
3.65e+02 fluids are used as they are more environment-friendly
3.45e+02 than oil-based fluids given the toxicity and non-
3.25e+02
3.05e+02 biodegradability of the oil-based fluids [18]. The
2.84e+02
2.64e+02 water-based TiO2 nanofluid used is procured in the form
2.44e+02
2.23e+02
of TiO2 nanopowder water dispersion (TiO2, 40 wt%
2.03e+02 avg. size 40 nm) from US Research Nanomaterials,
1.83e+02
1.62e+02 Inc. The desired percentage fraction of nanoparticles
1.42e+02
1.22e+02
are obtained by immersing this suspension in de-
1.02e+02 ionized water.
8.12e+01
6.09e+01 Water-based nanofluid is prepared with 1.5 % con-
4.09e+01
2.03e+01 centrations of TiO2 nanoparticles in de-ionized water
0.00e+00
using immersion method. TiO2 nanopowder water dis-
(a) persion (TiO2, 40 wt% avg. size 40 nm) was procured
from US Research Nanomaterials, Inc. TEM image
1.17e+00 shows the non-spherical shape of TiO2 nanoparticles
1.12e+00
1.06e+00 (Fig. 2). The sphericity of TiO2 nanoparticles is 0.87
3.45e-01
9.98e-01
(given by the manufacturer). Thermal conductivity is
9.40e-01 calculated using Eq. (2) [11, 20, 21]. Since the manu-
8.81e-01
8.22e-01 facturer supplied the nanofluid suspension in wt %, the
7.63e-01
7.05e-01 weight percent of nanoparticles, ω is converted into vol-
6.46e-01
5.87e-01 ume percent using Scherrer’s equation [22] as shown in
5.29e-01
4.70e-01
Eq. (1).
4.11e-01
3.52e-01 ωρw
2.94e-01 φ1 ¼
ω 
ω  ð1Þ
2.35e-01
ρw þ 1− ρ
1.76e-01
1.17e-01
100 100 p
5.87e-02
0.00e+00

(b) Where φ1 is the initial volume concentration, ω is the

Fig 1 Velocity contours for the jet of nozzles from MQL system. a weight percent of nanoparticles, ρw is the density of
Single-nozzle arrangement. b Three-nozzle arrangement water, and ρp is the density of the nanoparticles. The
stability of the mixture is ensured by maintaining the
pH of the aqueous solution of nanoparticles and
ultrasonication for about 2 h, resulting in no settling
very high speed. It was observed that the most effective MQL
of particles observed for the machining period. This
nozzle performance is with the three nozzles. For interrupted
machining processes, like end milling, temperature variations
are minimized by the use of continuous coolant flow rate.
Hence, three-nozzle arrangement was used for the study.

3 Experimental methods and materials

Three cutting environments including flooded (wet)

cooling, conventional (oil-based) MQL and water-based
nanofluid-MQL conditions are considered in the study.
Cutting fluid used for the conventional flooded machin-
ing is commercial water-soluble mineral oil (Supplier:
M-Tech, USA, available in 20-l packing, added 5 %
to water). The maximum flow rate for the conventional
flooded machining is 30 l/min. Vegetable oil-based cool-
ant (Coolube 2210, UNIST, Inc.) is used for conven-
tional MQL machining. Water-based TiO2 nanofluid is Fig 2 TEM image of TiO2 nanoparticles

results in a stable nanofluid and no observed settling of
particles for the machining period.
"  #
k p þ ðn−1Þ k f −ðn−1Þ ϕ k f −k p
kn f ¼ k f   ð2Þ
k p þ ðn−1Þ k f þ ϕ k f −k p
where k nf is the effective thermal conductivity of the
nanofluid, kf is the thermal conductivity of base fluid, kp is
the thermal conductivity of solid nanoparticles, ϕ is the nano-
particle volume fraction, and n is the empirical scaling factor
for the determination of the effects of nanoparticles’ shapes on
the thermal conductivity of the nanofluid or the shape factor.
The shape factor of the TiO2 nanoparticles is calculated using
the shape factor of a sphere, which is 3.0 [21, 11]. The thermal
conductivity of the base fluid (de-ionized water) and TiO2
nanoparticles used in this study are taken as 0.607 and
8.04 W/mK, respectively, at 27 °C [23]. Incorporating the
shape factor and percentage fraction, i.e., 1.5 %, increases
the thermal conductivity of de-ionized water to 0.632 W/mK.
End milling experiments were performed on a vertical ma-
chining center, VF-6 of HAAS. The material used for the
study is aluminum alloy (AA6061T6). The major alloying
elements in the alloy are Si, Cu, Mg, and Fe and the hardness
is 95 HB [24]. The specifications of the inserts used are given
in Fig. 3. Corner radius is 0.8 mm for all the inserts so the
effect of corner radius is similar in different cooling condi-
tions. Cutting parameter combinations for experimental pro-
cedures are listed in Table 1.
4 Results and discussion
Since tool flank wear has a great influence on the cutting
force, and the increase of tool flank wear results in a substan-
tial increase in the cutting force [25], hence, flank wear mech-
anisms are discussed in this study. Figures 4, 5, 6, and 7 show
the SEM images for the worn out uncoated tungsten carbide
inserts. It is observed that micro-attrition followed by micro-
Fig 3 Uncoated tungsten carbide (WC–Co 6 %) insert properties and geometry (M/s CERATIZIT)
Int J Adv Manuf Technol
abrasion, work material adhesion leading to edge fracture, and
edge chipping are the major wear processes of uncoated tung-
sten carbide tools. Edge fractures are also seen for some cases,
which resulted from the intermediate material built-up on the
cutting edge. Micro-attrition is seen as flat dull surfaces on the
flank face. These dull surfaces are due to the built-up layer
characteristic of aluminum that covers the tool surface under-
neath [26]. Cobalt binder and carbide grains are at the same
height and wear at the same rate. When in the continuous
rubbing between the flank face and newly generated surfaces,
this built-up layer is broken and micro-chunks of the tool
material are carried away with the fragments of the built-up
layer. Once the smeared aluminum layer is broken, cobalt
binder wears faster and carbides grains are seen projecting
from the cobalt binder [26, 27]. Another factor that may have
partly contributed towards abrasive wear is the abrasion
caused by the dislodged carbide grains from the tool cutting
edge or flank surface as these dislodged particles are carried
by the flowing chips [28].
SEM micrographs for a combination of parameters with
depth of cut at 3.0 mm, speed at 5500 RPM, feed rate of
440 mm/min and MQL flow rate of 0.48 ml/min are shown
in Fig. 4a. Adhesion and abrasion are the main wear mecha-
nisms. Edge chipping of length 92.62 μm is also observed.
For the cutting conditions with depth of cut at 3.0 mm, speed
is 5500 RPM and feed rate as 440 mm/min, the tool damage
condition in flooded cooling (Fig. 4b) is compared to the min-
imum MQL flow rate of 0.48 ml/min. The tool damage ap-
pears more severe in flooded conditions. This may be attrib-
uted to the higher temperature variation experienced by the
tool during intermittent milling operation, causing the brittle-
ness of the tool and enhancing its chipping and damage. SEM
images for the experimental design with depth of
cut = 3.0 mm, speed = 5500 RPM, feed rate = 440 mm/min,
MQL flow rate = 0.48 ml/min, and nanofluid volume fraction
of 1.5 % in Fig. 5. Higher feed rate, speed, and depth of cut
with lower MQL flow rate and moderate nanofluid volume
fraction result in adhesion and chipping of the edge. Adhesion
Int J Adv Manuf Technol

Table 1 MQL and nanofluid-

MQL cooling conditions Input cutting parameter Levels of input cutting parameters

Lowest Low Center High Highest

−α −1 0 +1 +α

Flooded cooling conditions (α = 1.682)

Cutting speed (RPM) 5237.0 5300.0 5400.0 5500.0 5563.0
Feed rate (mm/min) 279.0 318.0 379.0 440.0 479.0
Depth of cut (mm) 0.37 1.00 2.00 3.00 3.63
Conventional MQL conditions (α = 1.483)
Cutting speed (rpm) 5252.0 5300.0 5400.0 5500.0 5548.0
Feed rate (mm/min) 288.0 318.0 379.0 440.0 469.0
Depth of cut (mm) 0.52 1.00 2.00 3.00 3.48
MQL flow rate (ml/min) 0.39 0.48 0.65 0.83 1.00
Nanofluid MQL conditions (α = 2.0)
Cutting speed (rpm) 5200.0 5300.0 5400.0 5500.0 5600.0
Feed rate (mm/min) 230.0 300.0 370.0 440.0 510.0
Depth of cut (mm) 0.75 1.50 2.25 3.00 3.75
MQL flow rate (ml/min) 0.31 0.48 0.65 0.83 1.00
Volume fraction of nanoparticles (%) 0.5 1.5 2.5 3.5 4.5

Fig 4 SEM micrographs of uncoated tungsten carbide at speed = 5500 RPM, feed rate = 440 mm/min, depth of cut = 3.0 mm. a MQL
flow rate = 0.48 ml/min. b Flooded conditions
 Int J Adv Manuf Technol

Fig 5 SEM micrographs and EDS patterns for the machining condition with speed = 5500 RPM, feed rate = 440 mm/min, depth of
cut = 3.0 mm, MQL flow rate = 0.48 ml/min, nanofluid-volume fraction = 1.5 %

is a result of high heat generation due to higher feed rate and
depth of cut [29]. Attrition and adhesion wear mechanism are
characterized by the adhesion of work material on the tool
surface and mechanical removal of the tool material takes
place when the adhesive junctions are broken [30, 31].
Micro-abrasion is also observed as a result of broken adhesive
fragments rubbing against the tool surface [26, 31]. Carbide
grains protruding out from cobalt binder are observed with
dull flat surfaces (micro-attrition) around [26]. Spectrum 10e
shows adhered fragment on the cutting edge showing tool
material as well as work material fragments. Spectrums 39
and 40 show the gradual aluminum layer built-up on the cut-
ting edge. Low MQL flow rate is manifested by very low
concentrations of Ti on cutting edge.
SEM micrographs for a combination of depth of cut at
3.0 mm, speed at 5300 RPM, feed rate of 440 mm/min, and
MQL flow rate of 0.83 ml/min are given in Fig. 6a. Chipped
edge is seen with adhered work material; hence, edge fracture
is attributed to adhered work material. The formation of inter-
mediate built-up edge may have resulted due to adhesive char-
acteristics of the work material. This relatively stable built-up
edge starts acting as cutting edge, thus serving as a protective
cap or shield on the cutting edge and protecting it from further
flank wear [32]. With machining continued, this built-up edge
is dislodged from the tool edge, taking with it tool fragments
as well. A fracture of 113.6 μm is seen on cutting edge.
Smearing of the aluminum layer, i.e., built-up layer of alumi-
num, is clearly seen followed by micro-abrasion wear process.
Int J Adv Manuf Technol
Fig 6 SEM micrographs of uncoated tungsten carbide at speed = 5300 RPM, feed rate = 440 mm/min, depth of cut = 3.0 mm. a MQL
flow rate = 0.83 ml/min. b Flooded conditions
Built-up layer due to adhesion in the form of work deposited
on tool flank wear land is characteristic of aluminum machin-
ing [33]. For the cutting conditions with depth of cut at
3.0 mm, speed is 5300 RPM and feed rate as 440 mm/min,
the tool damage condition in flooded cooling (Fig. 6b) while
the MQL flow rate is compared to the minimum MQL flow
rate of 0. 83 ml/min. SEM micrographs show edge chipping
and large material adherence to the cutting edge in both cases.
For the nanofluid MQL machining conditions for depth of cut
at 3.0 mm, speed at 5300 RPM, feed rate at 440 mm/min,
MQL flow rate at 0.83 ml/min and nanofluid volume frac-
tion = 1.5 %, the tool SEM images and EDX patterns are
shown in Fig. 7. The feed rate and depth of cut are high with
high coolant flow rate but speed is medium. No edge damage
as well as built-up edge is observed, while abrasion and attri-
tion are seen on the cutting edge. A low cutting speed, micro-
attrition plowing effect is also observed because of the micro-
welding of aluminum in the cobalt phase of the cutting edge
[31]. EDX analysis shows aluminum layer built-up on the
cutting edge as compared to regions on flank away from
cutting edge. A ribbon-like layer of work materials, termed
metal deposit, is usually detected on the flank wear land due to
adhesion [33]. Higher percentage of aluminum as built-up
layer is seen near the cutting edge and the fractured edge.
Away from the cutting edge, aluminum percentage decreases
gradually. Higher concentrations of carbon and oxygen are
also recorded. Carbon presence is attributed to WC decompo-
sition and diffusion of carbon [33]. Magnesium is also detect-
ed, which may have come from the work material. Higher
MQL flow rate significantly reduces the Ti nanoparticles ad-
hesion on the tool surfaces. Surface finish of the machined
part is improved on account of no built-up edge and higher
fraction of nanoparticles acting as separating entity between
the contacting asperities [18, 34]. Nanoparticles increased
thermal and lubricating properties of nano fluids as compared
to other cutting fluids like high thermal conductivity, dynamic
viscosity, and heat transfer coefficient, resulting in reduced
frictional forces at chip tool interface and tool work interface;
hence the tool wear and surface roughness are reduced [35].
The major benefit from the water-based nanofluid-MQL is
 Int J Adv Manuf Technol

Fig 7 SEM micrographs and EDS patterns for the machining condition, with speed = 5300 RPM, feed rate = 440 mm/min depth of
cut = 3.0 mm, MQL flow rate = 0.83 ml/min, nanofluid-volume fraction = 1.5 %

shown in the edge integrity, i.e., edge chipping as well as edge

fracture is seen in very few cases especially with higher depth
of cut higher, higher feed rate, and lower cutting speed. This is
attributed to the cooling effect produced by the water,
resulting in the lowering of temperature in the cutting zone
[36].

4.1 Flank wear rate

Aluminum alloys are the most machinable among the metals

with a wide range of applications due to mechanical and cor-
rosion resistance with lower cutting forces as well as low Fig 8 Cutting tool wear variables [45]
Int J Adv Manuf Technol
Fig 9 Initial wear growth rate with speed = 5500 RPM, feed
rate = 440 mm/min, depth of cut = 3.0 mm, MQL flow rate = 0.48 ml/
min, nanofluid-volume fraction = 1.5 %
cutting temperatures [37, 38]. However, due to highly adhe-
sive characteristics of aluminum and its alloys, more effective
lubrication is required for these alloys although these are not
Fig 10 Flank wear development with time. a Flank wear after 5.0 m (12.0 min). b Flank wear after 10.0 m (24.0 min). c Flank wear after 15.0 m
(36.0 min). d Flank wear after 20.0 m (48.0 min)
hard and difficult-to-cut especially with alloys containing hard
inclusions such as aluminum oxide, silicon carbide, or free
silicon [38, 39]. On the other hand, machining of aluminum
alloys results in the generation of very fine metallic particles in
the form of ultrafine dust particles with longer airborne sus-
pension time; hence, they are harmful for the health of the
operator [40]. MQL has been effective in prolonging tool life
when machining steel specimens [41]. However, there has not
been the same rigorous investigations into the machining of
Al alloys [42]. Inconsistent views about the cooling conditions
for the alloy are observed in literature. Cutting fluids are nor-
mally considered unnecessary when machining aluminum al-
loys on account of relatively low cutting temperatures [43].
However, highly effective lubrication is required for alumi-
num alloys on account of high adhesive characteristics [44].
Unlike steel and other metals, cutting fluids are essential for
Al alloys machining in order to minimize the smearing effects
on the cutting tool edges and to reduce the surface roughness.
There are a few technical issues still related to aluminum ma-
chining which need to be resolved, such as tool wear and
machine reliability. The principal wear mechanisms in Al

alloys machining are burr formation, built-up-edge, as well as
surface roughness. Surface finish and burr formation in alu-
minum alloy machining are mainly used as tool life criteria as
it is difficult to observe tool wear in aluminum alloys machin-
ing [42]. A characteristic tool flank wear process is usually
expressed with the help of tool flank wear versus time curve
shown in Fig. 8 [45]. In the initial wear period, tool flank wear
develops faster than the uniform wear period which starts after
the initial wear period ends at inflection point. Since alumi-
num wear is hard to detect, it is difficult to evaluate its flank
wear rate. An attempt has been made to evaluate the initial
flank wear rate in aluminum with nanofluid-MQL. Initial
flank wear rate is thus evaluated, assuming an exponential
initial wear period is given by Eq. (3). The graph for the initial
wear growth is shown in Fig. 9.
 
y ¼ 29:134 e 0:0124 x R2 value ¼ 0:9427 ð3Þ
Progressive flank wear is shown in Fig. 10. Flank wear
after machining of 20 m shows huge built-up edge on the
cutting edge as well as on the rake face. The wedge area, the
initial contact point with the workpiece, is generally prone to
high stress concentration. A combination of chipping and
edge fracture starting from the wedge area of the insert was
found to be the initial wear mechanism.
5 Conclusion
In view of the cost-effectiveness, environmental friendliness,
and machining performance of minimum quantity lubrication,
the technique is applied for the machining of aluminum ma-
chining integrated with state-of-the-art nanofluids as lubri-
cants. Water-based nanofluids are the emerging potential cut-
ting fluids replacing the conventional oil-based MQL for in-
creased sustainability of machining processes as it combines
the higher cooling rate of water with the high lubricating ef-
fects of the nanoparticles. From the current study, adhesion
and abrasion are characterized as the major wear mechanisms
for aluminum alloy in end milling. Higher adhesion and edge
chipping are observed in case of flooded and oil-based ma-
chining conditions. Edge chipping is a result of built-up edge,
which acts as cutting edge, thus serving as a protective shield
on the cutting edge and thus protecting the edge from further
flank wear. With continued machining, these adhered work
material mounds get dislodged from the tool edge, taking
away with it the adhered work material, resulting in fractured
and chipped cutting edge. Aluminum machining is character-
ized with a deposit layer on the flank face. The adhesion and
abrasion wear as well as aluminum layer deposit in all the
three cooling conditions are almost comparable. The use of
water-based nanofluid MQL results in the unimpaired edges
or edge integrity, i.e., edge chipping as well as edge fracture is
Int J Adv Manuf Technol
not seen. This is attributed to the cooling effect produced by
the higher latent heat of vaporization of water, resulting in
lowering of temperature in the cutting zone. The results of
the study show that a combination of MQL with water-based
nanofluid lubricant is a potential cooling and lubricating ap-
proach for the machining substituting oil-based MQL as well
as flooded coolant conditions.
Acknowledgments The authors would like to thank Universiti Malay-
sia Pahang for providing laboratory facilities and financial support under
the Fundamental Research Grants Scheme (no. RDU110110) and Doc-
toral Scholarship scheme (GRS140310).
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