Materials and Manufacturing Processes

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A Review on Minimum Quantity Lubrication for

Machining Processes

Vishal S. Sharma, GurRaj Singh & Knut Sørby

To cite this article: Vishal S. Sharma, GurRaj Singh & Knut Sørby (2015) A Review on Minimum
Quantity Lubrication for Machining Processes, Materials and Manufacturing Processes, 30:8,
935-953, DOI: 10.1080/10426914.2014.994759

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 Materials and Manufacturing Processes, 30: 935–953, 2015
Copyright # Taylor & Francis Group, LLC
ISSN: 1042-6914 print=1532-2475 online
DOI: 10.1080/10426914.2014.994759

A Review on Minimum Quantity Lubrication for

Machining Processes
Vishal S. Sharma1, GurRaj Singh1, and Knut Sørby2
1
Department of Industrial and Production Engineering, Dr. B. R. Ambedkar
National Institute of Technology Jalandhar, Jalandhar, Punjab, India
2
Department of Production and Quality Engineering, Norwegian University of
Science and Technology, Trondheim, Norway

In the pursuit toward achieving dry cutting, air machining, minimum quantity lubrication (MQL), and cryogenically cooled machining
are the stepping stones. Nevertheless, machining is always accompanied by certain difficulties, and hence none of these methods has pro-
vided a complete solution. Hence, this article reviews various MQL methods used by various machining processes for different materials. It
also highlights the future work directions for research in this area.

Keywords Cutting; Fluids; Machining; MQL.

Downloaded by [14.139.61.212] at 00:55 13 June 2016

INTRODUCTION
Industry is seeking methods for reducing consumption
of lubricants during metal cutting operations because of
economical and ecological pressures. The overall objective
of the standards in the ISO 14000 family is to protect
environment in balance with socioeconomic require-
ments. The industries signing up for these standards will
need to quantify and prove reduction in the major five
elements, namely, harmful air emissions, water contami-
nation, waste management, land contamination, and
natural resource and raw material preservation [1–5].
Lubrication and heat removal are the basic ways to
keep the tool wear under control. It has been proved that
flood cooling, though very effective at lower cutting
speeds, gets ineffective at higher speeds because the
amount of heat generation is more and the coolant cannot
reach the critical areas (tool workpiece interface); hence
the interface cannot be cooled. Thus, minimum quantity
lubrication (MQL) comes out as another alternative that
can be studied in detail so as to reach the desired objective.
The goal of any machining operation is to lower the
machining costs by improving quality and productivity.
This is possible if machining is carried out at maximum
cutting parameters and at the same time able to achieve
enhanced tool life (TL). Another main focus is to have
minimum part rejections and minimum downtime.
Particularly in machining, a lot of parameters and their
interaction with each other affect the cutting perfor-
mance, e.g., cutting fluids (type, application method,
application quantity, flow rate, pressure, etc.); cutting
Received January 22, 2014; Accepted November 12, 2014
Address correspondence to Vishal S. Sharma, Department of
Industrial and Production Engineering, Dr. B. R. Ambedkar
National Institute of Technology Jalandhar, Jalandhar, Punjab
144011, India; E-mail: sharmvs@nitj.ac.in
tool (tool material, hardness, tool coating, tool size, tool
length, number of edges, angles, nose radius, etc.);
machine tool (rigidity, power, type of tool holder, tool
clamping, etc.); workpiece (material, hardness, size,
etc.); and machining parameters (speed, feed, depth of
cut, and type of operation) [6].
Although there have been many review articles on this
topic, this attempt has its own merits. A meticulous effort
has been made to study four different materials on four
machining processes. The main strength of the study lies
in the tabular and graphical representation. Moreover, it
also helps in the research being carried out by colleagues
in this area. It highlights the operational parameters that
have been left untouched and can be proved very useful
for any future studies in this field.
The article has been organized in a lucid manner. It
starts with an introduction, followed by separate head-
ing, discussing about the cutting fluids, MQL technique,
and the machining of the various materials and
processes, namely, turning, milling, drilling, and grind-
ing. Each review section is followed by a conclusion
summing up the main points that may be useful.
CUTTING FLUIDS
Cutting fluids play an important role in increasing the
productivity. During machining, cutting fluids are
employed to bring the cooling effect and lubrication
effect and to take away the formed chip from the cutting
zone [7].
The cooling effect plays an important role in reducing
the effect of temperature on cutting tool and machined
workpiece. The lubricant helps to remove the chips in
a better way from the rake surface as a result of a low
coefficient of friction. This may cause less built-up edge
(BUE) on the tool and may also provide better surface
finish. Moreover, it takes away the chip generated

935
 936
swiftly from the cutting tool and machined surface of the
workpiece. Furthermore, a certain amount of heat is
taken away by the chips [8, 9].
Cutting fluids can be classified into four categories:
cutting oil, soluble oils (emulsified oils, emulsions),
synthetic (chemical) fluids, and semisynthetic (semi-
chemical) fluids. Cutting oils are also called neat oil or
straight cutting oil as they are derived from petroleum,
animal, or vegetable origin. They are used at low tem-
perature and low speed cutting operations. Soluble oils
are basically oil droplets suspended in water. They are
manufactured by mixing oil with emulsifier agent in
water (which increases the stability of the emulsion). It
contains base oil, emulsifier, and other additives. Base
oil could be mineral oil or vegetable oil; other additives
include neutralization agents; and lubrication additives
such as antiwear, extreme pressure (EP) additives, bio-
cides, fungicides, and foam inhibitors could be used.
Emulsifiers disperse the oil in water in order to make a
stable oil-in-water emulsion [10]. The water in emulsions
can cause rust, bacterial growth, and evaporation losses.
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At high contact pressure and high temperatures, EP
additives like sulfur-, chlorine-, and phosphorous-based
chemicals will improve lubrication. Thus, this film
possesses low shear strength and good antiweld proper-
ties. Hence, EP additives can reduce friction and wear
effectively. Emulsion process allows the reduction of
heat, and hence higher cutting speeds in machining
could be achieved. Moreover, it can be diluted with
water to cut down the cost and risk of fire and lower
the rate of oil misting. The major drawback associated
with emulsions is the fungi and bacteria growth, which
increases health hazards and reduces the service life of
cutting fluids. So the use of chemical additives becomes
necessary in order to have bacterial growth control
in cutting fluids, but they are dangerous for both the
operators and environment. Mineral-based cutting
agents are extracted from petroleum. Furthermore, min-
eral oils have two types—paraffinic and naphthenic.
They have poor biodegradability and thus may pollute
the environment. Synthetic and semisynthetic cutting
TABLE 1.—Comparison of different cutting fluids [6].
Straight oils Soluble oils
Advantages
Excellent lubricity Good lubricity
Excellent rust control Good cooling
Disadvantages
Low cooling Rust control problems
Fire hazard Bacterial growth
Create mist or smoke Evaporation losses
Limited to low speed and
heavy cutting operations
V. S. SHARMA ET AL.
fluids are normally mixed with water and various chemi-
cals. The added chemicals tend to prevent rust, improve
lubrication, and reduce surface tension. Synthetic based
cutting agents tend to have good coolant properties, but
their lubricant properties are less than that of other cut-
ting fluid types. Semisynthetic cutting fluids are combi-
nations of synthetic cutting fluids and emulsions.
Semisynthetic cutting agents tend to comprise less oil (2–
30% oil), whereas synthetic cutting fluids contain no oil.
The relative advantages and disadvantages of different
types of cutting fluids are presented in Table 1.
In the recent time, the inclination of many researchers
has shifted to vegetable-based cutting fluids [11].
Vegetable oils have good lubricity properties, higher
flash point, and better boiling point, and as a result there
is less loss from misting. They have a higher viscosity
index, but thermal and oxidation stability of vegetable
oils is limited.
The types of lubricants for different machining
processes were quite closely studied by Baradie. He pro-
vided cutting fluids overview and further presented the
classification and composition of cutting fluids. In
addition, the issues of cleaning metal cutting technology,
concentrating on disposal of cutting fluids and their
recycling, were also presented [12, 13].
The choice of suitable cutting fluid is of prime impor-
tance as it could affect machining performance (TL,
cutting force [CF], surface roughness, power consump-
tion, etc.) and the selection is based upon parameters
such as workpiece used, material of the cutting tool,
and type of metal cutting process. The cutting fluids con-
taining sulfur and chlorine additives should not be used
with nickel-based alloys and titanium, respectively. In
general, cutting fluids with high lubricity ability are gen-
erally used in low-speed machining such as screw cutting
on difficult-to-cut materials, whereas cutting fluids with
high cooling ability are generally used in high-speed
machining [6].
The cutting fluids used during machining can affect
the health of operator negatively as the latter can form
mist owing to high pressure and temperature. This
Semisynthetics Synthetics
Good cooling Excellent cooling
Good rust control Excellent microbial control
Good microbial control Nonflammable
Good corrosion control
Reduced misting and foaming
Foam easily Poor lubricity
Stability is affected Easily contaminated by
by water hardness other machine fluids
Easily contaminated
by other machine fluids
 A REVIEW ON MINIMUM QUANTITY LUBRICATION
causes involuntary inhaling of these particles by the
operator, thus causing severe health issues. Mist, fumes,
smoke, and odors can even cause severe skin reactions.
Physical contact with cutting fluid may cause dermato-
logical problems for the operators. The machine tool
components need to be cleaned to remove any cutting
fluid residue which may require additional time and cost.
Furthermore, most of the cutting fluids used in machin-
ing are petroleum origin, and the disposal of petroleum-
based cutting fluids cause water contamination, air, and
soil pollutions.
Shokrani et al. in their work reviewed machining
of hard, nonhomogeneous, and ductile materials.
Further they identified the material properties that cause
trouble in their machining [14]. They are defined as
‘‘difficult-to-machine’’ materials based upon high cut-
ting temperature (CT) and short TL criteria. They could
not find any proper classification of the cutting fluids.
Many types of coolants are utilized in the industry
[15, 16]. But certain issues related to health and the
environment and factors related to the cost and
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disposal also exist [6, 17]. The methods that support
cutting are dry, cryogenic, and MQL cutting, but none
has provided a complete solution. This forms the
motivation for the current article, where a review of
MQL and its variants applied to various machining
processes have been carried out.
MINIMUM QUANTITY LUBRICATION
The conventional system of applying the coolant is
flood coolant system. In this, a bulk jet of the cutting
fluid is applied on the cutting zone, thus making it highly
uneconomical; moreover, there are problems concerned
to the reachability of the cutting fluid. The alternative
approach of mist lubrication has proven to be a better
alternative in which a mixture of air and cutting fluid
is applied onto the cutting zone. It has a better reach-
ability as a result of the high pressure while the flow rate
is 30 mL=h. This quantity is very small as compared to
flood cooling. The required air pressure varies from 2
to 6 bar [18–20].
MACHINING OF MATERIALS
Some of the issues related to machining of inconel,
titanium, and Al materials are presented in this section.
Machining of Inconel
These materials possess a very high temperature
strength alongside good corrosion resistance, thus
finding use in the aerospace industry. Due to such hard
nature, they are accompanied by certain problems such
as a poor TL as well as strength. Notch wear is another
problem encountered as repeated BUE is formed and
removed. This is also accompanied by the induction
of residual stresses that takes place as a result of the
metallurgical transformations.
The machining of inconel alloys could be carried
out by cemented carbide tools (K20 grade) at lower
speeds of 20–30 m=min. At higher speeds in the range
937
100 m=min, it is machined using coated carbide tools
but only under dry conditions. Oxidation resistance
is of prime importance in machining these materials,
and thus the PVD (TiAlN) coatings are most reliable
for this purpose. Besides this, they also possess proper-
ties like high temperature chemical stability, low thermal
conduction, and high hot hardness [21]. In case of more
higher speeds in the range of 200–700 m=min, ceramic
tools are being used, but they are prone to thermal
cracking. The Al2O3–TiC is also used to machine inconel
at higher speeds.
Thakur et al. performed a study on how the turning
parameters effected the surface characteristics of inconel.
The inserts used for cutting were made up of tungsten
carbide. Specific cutting pressure was found out to be
an important parameter besides the microstructural
alteration and even the microhardness (MH) were eval-
uated. The microstructural and MH analysis showed
that even the work hardening could be controlled by
optimizing the cutting parameters [22].
Machining of Titanium
Titanium along with its alloys possesses immense spe-
cific strength that imparts them properties like corrosion
resistance and fracture resistance, thus making them
a good candidate for aerospace applications. It has wide
engineering applications and is available in many forms.
The cost of these materials is somewhat high as compared
to their other variants because of the difficult extraction
processes and even problem in melting. In order to reduce
cost, they are produced by methods such as castings, iso-
thermal forging, or powder metallurgy. Even these parts
also require some kinds of machining (finishing).
Titanium and its alloys are difficult to machine because
the chips produced are very thin as a result of the small
area of contact of the tool. Also the thermal conductivity
of titanium and its alloys is very low while the stresses
produced are very high because of the low area of contact;
this produces a very high cutting temperature.
Titanium and its alloys are highly reactive to the tool
materials, especially at higher temperatures. Many prob-
lems in machining exist while machining these alloys.
Moreover, these alloys also have a very high reactivity
with interstitial oxygen and nitrogen, which in turn leads
to hardening. This hardening causes increase in the tool
wear, making the machining process very uneconomical.
Machine tool chatter is yet another problem encountered
while machining titanium because of its low modulus of
elasticity [23]. Ezugwu and Wang tried to optimize the
machining process of titanium and its alloys. The main
step that they laid stress was to eliminate the grinding
process that would lead to improved machinability as well
as reduce the machining cost. For this, they suggested
that cubic boron nitride (CBN) and diamond tools be
used for the finishing of these alloys. They also stressed
the use of straight tungsten carbide cutting tools for
machining these alloys as compared to the chemical vapor
deposition (CVD)-coated or creamic tools as they are less
reactive and posess a better thermal conductivity [24].
 938
Machining of Aluminum
Al alloys are most machinable of the common materials.
The low melting point of the material and the highest
coefficients of expansion along with relative softness and
elasticity make it necessary to dissipate the generated heat.
Otherwise, it is difficult to maintain tolerances of the work-
piece. Al alloys normally have significant amounts of Si
causing them to be adhesive, promoting rapid heat gener-
ation resulting in chip welding and BUE [25]. When com-
pared to the other materials, the machining of Al alloys is
much easies as it is a comparatively soft material, thus
resulting in a longer TL and much reduced CF. But in
addition to these properties, for a satisfactory outcome,
the other factors that also have to be fulfilled are the prob-
lems of material adhesion as well as the BUE formation
that shortens the TL and causes other machining prob-
lems. Thus, a properly optimized tool geometry as well
as the machining parameters are highly recommended
for the machining of Al and its alloys in order to achieve
proper results [26].
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MACHINING USING MQL: TURNING
Turning is a process that consists of the tool and a stiff
tool bit that traces a helical tool path when the work-
piece revolves. It is the machining process for cylindrical
items [27].
Thakur et al. attempted to improve the machinability
of the inconel alloy by using the MQL process. They
optimized the various parameters like pressure, feed,
cutting speed, frequency of pulses, and the direction
of application. The optimum values found for various
parameters were 13 MPa, 0.05 mm=min, 40 m=min, 300
pulses=min, and inclined in the direction of the cutting
fluid. In another study, Thakur et al. performed
experimentation on inconel 718 and proved that MQL
could be used to perform machining of these super
alloys; furthermore, the optimal cutting parameters were
obtained [28]. They also presented correlations and con-
firmation tests for the flank wear. The scope of the cur-
rent study is rather limited as only the tool wear has
been studied, which could be extended taking into
account the surface roughness and temperature measure-
ments. Also from Table 1, Che Haron et al. also per-
formed turning of inconel and studied the surface
integrity using a coated carbide tool and thus evaluating
the various parameters. Topographic study on turning
surface indicated that surface roughness increased pro-
portionately with feed rate. Microstructure analysis elu-
cidated that plastic deformation occurred during high
cutting speed, and the deformation direction was parallel
to the cutting direction. Higher values of MH were
obtained at top machine surface which gradually reduced
to base material hardness between 320 and 280 HV [29].
Inconel (refer Table 1) was machined by Vasu and
Pradeep Kumar Reddy under MQL (with nanoparticles).
They found that surface roughness (SR), temperature,
CF, and tool wear (TW) lowered for MQL as compared
to dry or wet machining [30]. The major noticeable point
about the article seems to be the range of speed while
V. S. SHARMA ET AL.
performing the experiments—it is toward the lower side.
Experiments were conducted on the machining of inconel
718. The objective of the study was reduction of pro-
duction cost and environmental safety. Coated carbide
tools and an upswing in the speed proved out to be the
leading factors in achieving the target. During the com-
parison of the residual stresses, it was found out that
tensile stress could be controlled by using a lubricant,
although its effect could be reduced by increasing the
cutting speed [31]. Investigations were made in all the
three methods of cooling and for both continuous and
interrupted types for Ti6Al4 V by using FEM to simulate
its deformation process. It was found that in continuous
cutting, dry cutting was effective at reduced cutting para-
meters. MQL gave better results at higher feed rates and
speeds as well as for interrupted cooling. Thus, MQL is a
more suitable cooling lubricant than flood cooling [32].
Liu et al. worked to prove that dry machining and
MQL could be the most suitable processes for machining
titanium. Tool coating was one key factor to realize
high-speed machining and green manufacturing. It was
observed that (nc-AlTiN)=(a-Si3N4) tool only underwent
an adhesive wear while the (nc-AlCrN)=(a-Si3N4) tool
underwent all forms of wear. The wear rate for
(nc-AlTiN)=(a-Si3N4) tool was also found out to be
lower resulting in a prolonged TL [33]. Turning experi-
ments were also performed for titanium alloys under
MQL condition. Vortex tube in the MQL setup was used
to help in the cooling of the compressed air. They evalu-
ated processing efficiency, CF, and SR. They reported
feed rate as a vital factor for affecting SR and CF.
Results of MQL were found out to be in between dry cut-
ting and flood cutting. CF obtained in MQL cutting was
a little larger than that in flood cutting [34]. Aluminum
turning was carried out by Shashidhara and Jayaram
under MQL conditions (modified versions of the cutting
oils) and they measured CF. They stated that the veg-
etable oil Jatropha curcas gave the best results while
machining. They also stated EJME (epoxidized Jatropha
methyl ester) as a better cutting fluid for machining
aluminum as compared to other fluids [35]. The para-
meter selection is very good based upon the high input
variations. For further improvement in the results, the
same experiments could be conducted for coolants such
as vegetable oils, and the results could be compared.
Turning of steel has been carried out by many
researchers in the past (Table 2). Attanasio et al.
achieved success in proving that MQL gave a better
TL when applied to the tool flank as compared to when
applied to tool rake [36]. A two-variant system has been
used that gave a linear trend in the results. A
three-variant system may give different results, although
the number of experiments may increase marginally. The
same studies could also be done for other materials as
well. Li and Liang proved that MQL had a dominant
effect on CT and also helped in reducing TW. It was also
reported that MQL reduced the tangential cutting force
as well [37] (Table 3). A large number of experiments
were performed on MQL by turning steel samples at a
large number of combinations of speed and feed.
 A REVIEW ON MINIMUM QUANTITY LUBRICATION 939
TABLE 2.—Turning of various materials under MQL (part I).

References Work material Tool material Cutting parameters Cooling types used Type, conditions Parameters evaluated=DOE

Inconel
[30] Inconel 600 alloy Multicoated Vc: 40, 50, 60; Dry, MQL, T:vegetable oil-based; p: 5 bar; Tool tip interface
carbide fn: 0.08, 0.12, MQL q: 100 temperature, CF, TW,
0.16; (nanofluids) MQL with nanofluids (4% chip
ap: 0.4, 0.8, 1.2 volume fraction of Al2O3 and formation=Taguchi
6% volume fraction of Al2O3)
[31] Inconel 718 Coated carbide Vc: 40, 60, 80; Dry, wet CF, SR, RS, tool life
fn: 0.1
ap: 0.5
[29] Inconel 718 TiAlN-coated Vc: 90, 120, 150; MQL q: 100 SR, ST, MS, MH=RSM
carbide inserts fn: 0.15, 0.25, SpDr: Target rake and flank
0.25; region
ap: 0.3, 0.4, 0.5
[28] Inconel 718 Tungsten carbide Vc: 40, 60; MQL T: water-soluble cutting oil; Flank wear=Taguchi
(WC-Co) insert fn: 0.08, 0.20; p: 100, 130; q: 300, 600
ap: 0.5 N: 200, 300 Pulses=min
SpDr: inclined and vertically
downward
Titanium
[34] Ti-6Al-4V Tungsten carbide Vc: 40 to 160; Dry, wet, MQL T: vegetable oil; q: 16; p: 7; SR,CF=Taguchi
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inserts (nano- fn: 0.05 to 0.2; SD: 20; SpDr: Flank face
multilayer ap: 0.3 to 1.2
coatings)
[33] Ti-6Al-4V (nc-AlTiN)= Vc: 120 m=min Dry, MQL T: vortex tube and vegetable Tool life, flank wear
(a-Si3N4) and fn: 0.1 mm=rev oil; p:.7 Mpa
(nc-AlCrN)= ap: 1.2 mm quantity consumed: 16 mL=h
(a-Si3N4)
coatings
Aluminum
[35] AA6061 Cemented Vc: 110, 138, 175, MQL T: Pongam, Jatropha, CF
carbide tool 221; mineral oil Nozzle: 2; p: 3
fn: 0.1, 0.18, 0.25;
ap: 0.5, 1.0, 1.5

Uncoated carbide inserts were used for this purpose.
Important factors such as CT were found to be reduced
while the dimensional accuracy improved by using MQL
[38]. Another series of experiments studied the effect of
MQL by vegetable oil on CT, SR, DD, and TW while
turning steel at different combinations by using
uncoated carbide inserts. It was seen that the dimen-
sional accuracy improved while significant reduction
was noted in TW, SR, and CT [39]. The best part of
the above studies was the variation of the cutting speeds
and the depth of cut (DOC) has been varied properly as
well. But the MQL parameters such as pressure and the
flow rate could be varied. Dhar et al. conducted experi-
ments to compare the performance of MQL and dry
lubrication in AISI-1040 steel. The results showed
reduction in the friction and the BUE formation. Better-
ment in the chip and tool interface was noticed while the
cutting zone temperatures saw reduction [40]. In another
study, MQL was proved to be a feasible alternative to
the conventional cutting fluid. Variations in cutting
force, CT, CTh, and surface roughness under different
machining conditions were studied. A reduction was
observed in the tool–chip interface temperature by
20–30%, CF by 5–12%, CTh up to 12–17% over dry
turning while the surface finish improved [41]. The vari-
ation in the input parameters has been done very nicely,
but the depth of cut of 0.4 mm was on the lower side.
Choosing a depth of cut around 1 mm would have given
more meaningful results along with variations in the
MQL parameters. Ali et al. compared dry cutting and
MQL, measured CTh ratio, CT, CF, TW, and surface
roughness. It was observed that CTh ratio had an upward
trend with an upward variation of speed and feed values.
CF witnessed a downward trend as a result of the high
velocity MQL jet that in turn reduced the chip load.
Another favorable point observed was the reduction in
TW and improvement in the surface finish [42]. Sharma
and Sachdeva evaluated machining under MQL, flood
cooling, and dry conditions in terms of TW and surface
roughness. The turning experiments on mild steel using
coated carbide tool indicated that MQL was a better
option as compared to other two cooling conditions
[43]. Experimental study was carried out on steel
samples for turning using the flood cooling, MQL
cooling, and pulverization. In order to carry out the
study, high-pressure jets of the cutting fluid were used
and applied to different regions of the cutting zone or
the cutting tool. The results proved that an application
 940
of the fluid jet to the tool chip interface let to reduction in
TW as well as the CF while the TL witnessed an upward
trend [44]. Observations were also made on the surface
properties after turning AISI 316 L steel and compared
the results for dry and MQL processes. The influence of
variation in the cutting parameters on factors such as
SR, CF, and defects on the surface was shown and a
regression analysis of the process was performed in which
SR was taken as a function of cutting zone cooling and
lubrication conditions. Finally, it was concluded that by
proper selection of the vital parameters, results of MQL
and dry cutting could be comparable to the flood cutting
[45]. The studies on tool wear and tool life could also be
done following the same parameters and using different
materials. Gordana et al. suggested MQL as a good
alternative for conventional machining processes. They
studied carbon steel samples for turning process by vary-
ing the various machining parameters, and the output
parameters were CF, SR, TW, TL, and chip shape [1].
Cica et al. performed turning on carbon steel samples
and compared the conventional, MQL, and high pressure
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jet assisted machining (HPJAM) techniques and took CF
as a response parameter. It was found lower in both cases
as compared to the conventional machining process. CT
was also found lowered for MQL process as a result of
the fragmentation of the fluid that led to better chip–tool
and work–tool interaction [46].
Thus, the turning of the inconel alloys at lower speeds
could be carried out by cemented carbide (K20 grade)
tools, while for the higher cutting speeds in dry
condition it could be performed by using the coated
carbide tools. Straight tungsten carbide could be used
for the machining of titanium alloys, as the CVD-coated
carbides and ceramics react with titanium.
The use of nanoparticles along with MQL is recom-
mended for inconel alloys. The use of a vortex tube
can provide cool air, which can further enhance the
effectiveness of MQL while turning of titanium.
Furthermore, results of MQL turning of inconel alloys
were intermediate between dry cutting and flood cutting.
MQL was effective for turning of aluminum. Turning
steel alloys with carbide and coated carbide tools have
been studied well. Most of the authors have indicated
adequate betterment in performance with MQL machin-
ing compared to dry machining, and more meaningful
results could have been obtained if it was also compared
with flood machining (just a few existing studies). It was
found that MQL primarily reduced the CT, which
enhanced the chip–tool interaction, thus improving the
tool life and reducing CF. Lesser loss at the tool tip
and lesser wear led to improved surface properties.
From the review, it is very much evident that MQL is
a better process for machining of steel samples providing
better results.
MACHINING USING MQL: MILLING
Table 4 shows the information of various researches
carried out on the milling process. Zhang et al. machined
inconel 718 using both dry cutting and MCQL
V. S. SHARMA ET AL.
technique, where a mist of vegetable oil and cryogenic
air was applied on the cutting zone. TW and CF were
the output parameters. It was reported that TW
occurred as a result of severe chipping of the cutting
edge of the workpiece. MCQL was observed to give
a better TL, which was as much as 1.57 times when
compared to that of the dry machining. While observing
the CF, again MCQL showed lower values as compared
to the dry systems, giving credit to the lowered frictional
forces at the various interfaces as a result of the lubri-
cation effect of the vegetable oil [47]. The work done is
having a huge scope of further developments as more
speed feed combinations could be used along with the
application of various optimization techniques. Machin-
ing of titanium was carried out using dry cutting, flood
cooling, and MQL techniques. Input parameters such
as speed, feed, depth of cut, and tool load were primarily
taken into account. TL and CF values were observed
and compared. It was observed that in case of MQL,
lower values of TL and CF were obtained when
compared to the dry cutting, and the values were also
comparable to those of the flood cooling systems. It
can be interpreted that MQL has a potential to replace
the flood cooling system on account of its cost factor
as the need of cooling was fulfilled by well-focused
coolant jets at the cutting zone rather than flooding
the whole area, thus saving huge amount of cost [48].
Liu et al. performed machining tests for titanium using
MQL process. They varied MQL parameters such as
nozzle angle, pressure of spray, and the rate of lubricant
flow [49]. It could be seen that these input parameters
had an anchoring effect on the CF as well as on the tem-
perature. The optimization of the air pressure as well as
the distance of spraying can have a major effect on the
efficiency of the milling process. Moreover, the effective-
ness of MQL diminished at too large or too short
distances in terms of the penetrability of the MQL mist.
The angle of nozzle spraying did not have a significant
effect on the process while the rate of oil flow had a huge
effect on the results. The study could be complemented if
the variation of the coolant oil on the basis of its density
and viscosity was also studied. In a recent study, Cai
et al. performed milling of Ti-6Al-4 V, giving stress on
the rate of oil supply while MQL machining in order
to study its effects on the various parameters. It can
be interpreted that MQL mist formed was capable of
penetrating into the cutting zone voids in a very efficient
manner acting as a very good lubricant. This lubricating
effect resulted in a significant reduction in CF and SR.
It was also observed that the increase in supply from 2
to 14 mL=h caused drastic reduction in both CF and SR.
In addition to this, it was also observed that the increase
in the rate of fluid flow was effective only till 10 mL=h
and had insignificant effects thereafter. MQL was also
observed to cause reduction in the chipping length with
increase in the fluid flow rate [50]. Another series of
experiments used uncoated carbide inserts to perform
machining experiments on Ti-6Al-4 V by using several
combinations of cooling techniques such as dry, wet,
MQL (without cooling air), and MQL (with cooling
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TABLE 3.—Turning of various materials under MQL (part II).

References Work material Tool material Cutting parameters Cooling types used Type, conditions Parameters evaluated=DOE

Steel
[44] SAE EV-8 Coated cemented Vc: 140, 170, 200; Combined flood, MQCF, Flood: 5% solution of semisynthetic TL, SR, CT, CF, chip form, chip
carbide (TiCN, Al2O3, fn: 0.1, 0.15, 0.2 MQL emulsion, MQL T: vegetable-based compression rate, and MS
and TiN) ap: 0.5, 0.75, 1 lubricant
SD: 50
air p: 4
[45] AISI 316L steel Carbide (PVD coating Vc: 82, 164, 255; Dry, flood, MQL Flood: ARTEsol SUPER EP, CF, surface properties
composition: TiAlN) fn: 0.08, 0.27, 0.47; q: 4 L=min
ap: 0.5, 1, 2 MQL T: Accu-Lube 8000 oil
NN: 2 nozzle directing rake face
and principle and auxiliary flank
MQL velocity: 30 m=s, p: 3.5;
q: 10, 20, 50
[1] Carbon steel Carbide
Vc: 210, 310, 400; Flood, MQL Flood p: 3, q: 2 L=min CF, TW, SR, chip shape=RN,
C45E fn: 0.224, 0.28, 0.355, 0.40; MQL p: 3, q: 30 ANN
ap: 1.5, 2, 2.5
[46] Carbon steel SNMG 1204 08 NMX Vc: 210, 320, 400; Flood, MQL, HPJAM Flood p: 3, q: 2 L=min CF=ANN,ANFIS
Ck45E fn: 0.224, 0.280, 0.355, MQL p: 3, q: 30
0.400; HPJAM p: 500 bar, q: 2 L=min
ap: 1.5, 2.0, 2.5
[42] Medium carbon Uncoated carbide (P30) Vc: 68, 95, 133, 190, 266; Dry, MQL T: VG-68 cutting oil; q: 150 mL=h, CTh ratio, CT, CF, TW, SR
steel fn: 0.10, 0.12, 0.14, 0.18, Air p: 23, Oil p: 25
0.20;
ap: 1.0, 1.5

941
[41] Alloy steel EN-31 Tungsten carbide Vc: 24, 39, 112, 189; Dry, MQL T: 10% boric acid with SAE Chip–tool interface temperature,
fn: 0.06, 0.10, 0.15; 40 base oil CF, CTh, SR, chip breaking
ap: 0.4
[40] AISI 1040 steel Carbide (P30) Vc: 72, 94, 139, 164; Dry, MQL T: Mobil Cut-102 CT, CRC, CF, TW,SR, DD
fn: 0.10, 0.13, 0.16, 0.20; p : 8.0, q: 200
ap: 1.5 SpDr: chip–tool and the work–tool
interfaces
[38] AISI 1040 steel Carbide, SNMM 120408 Vc: 64, 80, 110, 130; Dry, flood, MQL p: 7, Temperature, CR, DD
(P30) fn: 0.10, 0.13, 0.16, 0.20; q: lubricant: 60
ap: 1.0
[39] AISI 1060 steel Uncoated carbide, TTS, Vc: 72, 94, 139, 164; Dry, MQL p: 7; SR
SNMM 120408 fn: 0.10, 0.13, 0.16, 0.20; q: 60
ap: 1.5
[36] Normalized CNMG 12 04 04 PM— Vc: 300; Dry, MQL T: Ester oil with EP additive TW
100Cr6 steel 4025 fn: 0.20, 0.26; p: 2.5
ap: 1; q: 20
CL: 50, 200 SpDr: on the rake and on the flank
[37] AISI 1045 Carbide Vc: 45.75, 91.5, 137.25; Dry, flood T: Vegetable oil Coolube 2210 TW, PC, aerosol generation rate
fn: 0.0508, 0.0762, 0.1016; MQL Flood: Valcool cutting fluid þ water;
ap: 0.508, 1.016, 0.762 q: 15 L=min
[79] 0.45%C carbon Coated carbide (P35) Vc: 240, 300; MQL T: vegetable oil (100% fatty acid) TW
steel (TiC=TiCN=TiN) fn: 0.12; SrDr: 20 to the flank of the tool shank
and 15 to the flank of the tool insert;
q: 7.0

Vc: cutting speed (m=min); fn: feed per revolution (mm=rev); ap: depth of cut (mm).
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TABLE 4.—Milling of various materials under MQL.

References Work material Tool material Cutting parameters Cooling types used Type, conditions Parameters evaluated=DOE

Inconel
[47] Inconel 718 Cemented carbide, coated TM: Down Dry, MQCL T: vegetable oil; Air p: 1.5; CF,TW
TiAlN þ TiN Vc: 55; fz: 0.1; ap: 0.5; ae: 1 Air temperature:30; Air q:
zn ¼ 1; fn ¼ 0.1 500 L=min
Number of nozzles: 2 (rake and
flank)
Oil q: 8
Titanium
[48] Ti-6Al-4V alloy Carbide tool Vc: 40–140; fn: 0.05, 0.3; Dry, flood, MQL Flood: fully synthetic water soluble CF and TW characteristics
ap: 0.5; ae: 2–8; zn: 2 coolant (glycol) ratio: 1: 20;
MQL: vegetable oil; p: 5.2, q: 2–10
DM: 3.7
[50] Ti-6Al-4V Coated inserts (TiAlN) Vc: 200; fz: 0.25; ap: 5; ae: 1 Dry, MQL T: Vegetable based; CF, SR, and TW
zn: 2; fn ¼ 0.5 Oil q: 2, 6, 10, 14; air p: 6, air q: mechanisms
125 L=min;
SpDr: 135 , ND: 25
[51] Ti-6Al-4V Uncoated cemented carbide Vc: 62.8; fn: 0.075; ap: 1; ae: 8 Dry, Wet, MQL MQL oil: synthetic based ester, SR, flank wear, CF, chip
density: 0.92 g=cm3 at 20 C morphology
viscosity: 47 mm2=s at 40 C
Cooling air: 0 C, 15 C, 30 C,
45 C
Flow: 280 L=min
p: 7 bar

942
[49] Ti-6Al-4V Coated carbide (TiAlN) Vc: 150; fz: 0.05; ap: 5; ae: 1 MQL Air p: 1, 3, 5, 7; CF, cutting temperature
zn ¼ 1; fn ¼ 0.05 Air q: 125 L=m;
ND: 15, 25, 35, 45;
Oil q: 2, 4, 6, 8, 10;
SpDr: 45, 90, 135
Aluminum
[25] Al Coated tungsten carbide Vc: 135, 150, 165;Vf: 400; ap: 3 Dry, flood, Airtx vortex tube (Model 20008) CF, power, and
cooled air, inlet pressure of 85 psi chilled air SR=Taguchi
MQL, cooled 5 C;
air þ MQL T: traditional emulsified cutting
fluid; SD: 25 mm
[53] Al 6063-T6 ND Vc: 35, 56, 88; Vf: 180, 250, 355 MQL T: vegetable oil; TW,SR=GA, ANOVA
ap: 1, 1.2, 1.4 p: 4; q: 300, 600, 900
[52] AA7075-T6 WC-Co alloy with 6% n: 260, 780, 1330; Vf: 20, 40, 80 Flood, MQL T: boron oil and water; SR=ANOVA
cobalt, HSS, TiCN-coated ap: 1; ae: 6 Flood: q: 1 L=m;
HSS tools MQL q: 300; p: 5;
MQL ratio:9:10 and 1: 10;
Flood ratio:1:10
Steel
[57] STAVAX TiAlN=AlCrN Vc: 50; fz: 0.04; ap: 0.2; ae: 0.4; zn: 1; Flood, mist 1: 93 vol% liquid paraffin oil and Surface study, TW,
(modified 420 nano-multilayer-coated, fn: 0.04 7 vol% cyclomethicone sprayed in EDX=Raman
stainless steel) TiAlN single-layer-coated, mist spectroscopy
and uncoated carbide MQL q: 0.2 L=h; p: 0.2 MPa
tools 2: an emulsified water-based

(Continued )
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TABLE 4.—Continued

References Work material Tool material Cutting parameters Cooling types used Type, conditions Parameters evaluated=DOE

coolant (9% concentration of Shell

Dormous BL oil)
[56] Forged steel YBG205, APKT11-T308- Vc: 219.8; ap: 0.5; fz: 0.14 Dry, flood, MQL Flood: 20 L=min; TW,SR, Chip
(50CrMnMo) PM ae: 8; zn ¼ 1; fn ¼ 0.14 MQL q: 13.9, 43.8, 58.4; morphology=RSM
Air p: 2, 3.5, 6;
air delivery: 280 L=min;
Nz direction in relation to feed: 0,

943
60, 120, 180 ;
Nz elevation: 30, 45, 60 ;
Nz Distance: 10, 20, 30
[54] NAK80 mold Coated carbide (TiAlN and Vc: 300, 400, 500; Dry, MQL T: Synthetic ester Tool life, SEM
steel TiN) fz: 0.10, 0.15, 0.20; p: 4.5; q: 10 micrographs, and EDAX
ap: 0.3; ae: 5 analyses of cutting tools
zn ¼ 1; fn ¼ 0.10, 0.15, 0.20

Vc: cutting speed (m=min); ae: radial depth of cut (mm); ap: axial depth of cut (mm); fn: feed per revolution (mm=rev); fz: feed=tooth(mm=tooth); Vf: feed per minute (mm=min); zn: available cutter teeth.
 944
air). The results can be interpreted in terms of response
parameters like SR, CF, and TW as well as the chip
morphology. MQL along with the cooling air has the
potential to give the best results in terms of the response
parameters causing drastic reductions in the SR and TW
values, thus validating it as a good alternative for the
traditional techniques [51]. Tosun and Huseyinoglu
performed milling of Al while using many tool materials
such as TiCN, high speed steel (HSS), and WC-Co. It
can be concluded that machining carried out with
WC-Co tools can give the best possible results when
compared to the other variants. It can also be inter-
preted that the efficiency of MQL process could be eval-
uated in terms of the penetratability of its mist
produced. The concentration of the mist or the volu-
metric concentration ratio had a dictatorial effect on
the parameters such as SR, where a concentration of
1:9 gave much better results as compared to the ratio
9:10 in terms of the penetration effect of the mist into
the cutting zone voids [52]. The work done could further
be enhanced by taking into account the nozzle design
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and performing the experiments with nozzles of different
specifications. Al machining carried out by Boswell and
Islam successfully demonstrated a suitable MQL environ-
ment for end milling. They reported that MQL had the
lowest cutting force followed by MQL þ cooled air, indi-
cating an efficient machining performance. In addition,
MQL and MQL þ cooled air achieved surface finishes
as compatible to that of flood coolant. They combined
air cooling þMQL in a suitable redesigned nozzle.
Although air cooling using miniscule amounts of
vegetable oil was not a completely dry process, but it
was quite close and therefore is sustainable [25]. Murthy
proposed an algorithm based on artificial neural network
model to predict surface roughness and TW for machin-
ing of Al under MQL. They concluded that the optimum
parameters among the studied, for minimum surface
roughness and TW, were cutting speed of 88 m=min, feed
velocity of 180 mm=min, depth of cut of 1.4 mm, and
coolant flow rate of 600 mL=h [53]. In another study, har-
dened steel was machined, and observations on the results
were made [54]. MQL has the potential to give a better
tool performance at all levels of the cutting speeds when
compared to the dry cutting process. This could be
explained theoretically in terms of the formation of a
layer of oxides on the interface of the work and the tool,
as the MQL provides additional oxygen to the interface.
This layer acts as a protection film to safeguard the tool
material from diffusion with the work material, thus
improving the TL. When taking the cutting speed into
account, it can be interpreted that at speeds higher than
the optimal values, significant downfall was observed in
the TL, mainly due to the absence of the protective layer
that ultimately led to thermal cracking and ultimately
shortening TL. Iqbal et al. machined hardened tool steel
of hardness 62 HRc by using MQL and studied the
effects of the various cutting parameters on SR and
TL [55]. An approach different from others was applied
in this case where dispersive spectroscopic analysis
and electron microscopy were performed. It may be
V. S. SHARMA ET AL.
concluded that at lower values of feed and speed,
marginal betterments were indicated in the TL and SR
values. Further, the main modes of tool failure were
indicated as chipping as well as the adhesion, which
due to the effect of MQL got lowered, thus improving
the TL. Yan et al. performed experiments to investigate
the various types of lubrication, i.e., dry, flood, and
MQL cooling, to improve the machinability during the
milling of forged steel. They selected TW and SR as
the output parameters. The variants of MQL taken as
input were direction, elevation angle, pressure, and flow
rate. It was reported that MQL resulted in a lowered TW
and SR along with a significant reduction in the CT as
well. The optimal values were obtained as nozzle pos-
ition 120 and angle of elevation as 60 and the
optimal distance came out to be 20 mm that ultimately
resulted in a better TL and lowered SR values. It was
also reported that the increase in flow rate from 43.8
to 58.4 mL=h led to an insignificant change in the flank
wear value [56]. Liew et al. conducted milling of
STAVAX (modified 420 stainless steel) using TiAlN
single-coated, multicoated, as well as uncoated carbide
tools. Both flooding and MQL processes were studied
and compared. It was reported that misting caused
a protective oxide layer to be formed on the interface,
thus lowering frictional forces and resulting in a proper
machinability when compared to the flooding technique.
The cost also reduced and so did the chances for the
abrasive wear [57].
While performing the milling operation using MQL, the
TL as well as the CF values can be improved by using the
vegetable oil while machining Inconal 718. Another way to
further improve the machining effectiveness of MQL
milling is to use cryogenic compressed along with the lubri-
cant droplets, thus reducing the TW rate. Titanium
milling could be successfully achieved under MQL. MQL
also helped in making the tool coating last longer as
compared to the flood cooling method. Moreover, by regu-
lating oil supply rate, desirable results could be obtained.
Also for the titanium alloys, it is observed that MQL
with cooling air gives better results of TW and SR as
compared to the MQL without the air.
Al alloy milling under MQL was also successfully
demonstrated at different cutting parameters. It was
reported that the results of cold air (vortex tube) þ MQL
were comparable with that of flood cooling. The
vegetable oil was also effective in the Al alloy machining.
The volumetric concentration test by one of the
researchers proved that a concentration ratio of 1:10
while performing MQL was better than the ratio of
9:10 [52].
Stainless steel while being low speed milled gave better
results with TiAlN=AlCrN nano-multilayer tools with
coatings. Excessive chipping could be reduced by using
mineral oil in a small quantity as spray.
MACHINING USING MQL: DILLING
The performance of the drilling process is greatly
affected by the type of the cutting fluid used. Haan et al.
 A REVIEW ON MINIMUM QUANTITY LUBRICATION
conducted the drilling of Al and gray cast iron so as to
study the functionability of the cutting fluids. They used
the feed, hole depth, material, speed, cooling condition,
and temperatures as input parameters, while the
response parameters were the torque, hole quality, chip
morphology, and SR [58]. It could be interpreted that
the cutting fluids help in reducing the BUE formation.
Moreover, the coolant not only removes the excessive heat
from the cutting zone but also helps in the lubrication of
the margins of the drill. This has been a very good study
in the sphere of drilling technology, but comparing with
the present-day technology it lacks many advanced techni-
cal approaches. But the work could well be used as a base
for further studies.
Rahim and Sasahara machined inconel 718 using
synthetic esters and palm oil (Table 5). They found that
MQL using such coolants improved the factors such as
SR and microhardness and also reduced the surface
defects [59]. Experiments were also conducted for drill-
ing Ti-6Al-4 V using both MQL and dry cutting to inves-
tigate for improvements when using MQL. They found
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the minimum TL in dry cutting [60]. The primary reason
for this can be inferred as the lack of lubrication that in
turn results in a severe chipping of the tool. MQL can be
seen as a better method on the basis of favorable results
for factors such as TL, temperature, torque, and force.
The reason for the selection of palm oil as a lubricant
was its property to create a thin layer that acts as a lubri-
cant. Very apt results have been provided in the field of
surface roughness, while drilling is very important to
take into account the heat dissipation and the tempera-
ture. There is a huge scope of studying the temperature
effects by varying the coolants and studying the results.
In yet another study, stress was laid on the temperature
observations while drilling titanium alloy Ti6AlV. Dur-
ing these experiments, uncoated K10 carbide drills as
well as the TiAlN-, CrCN-, or TiCN-coated drills were
utilized [61]. Another difference in the approach was
the use of both external and internal MQL where the
coolant was applied through the drill. It could be con-
cluded that internal MQL was more efficient as com-
pared to the external with an efficiency to nearly
double its counterpart in terms of temperature. Highest
temperature was recorded for the uncoated drills where
the MQL was applied externally. An important factor
that should also be taken into account is the chip mor-
phology and the chip breaking ability of the method
used, as it primarily determines the quality of the hole.
Fox-Rabinovich et al. studied the different coatings
and their effect on the TL while drilling using cemented
carbide drills. They made comparison between both
MQL and the flood cooling techniques. Three sets of
experiments were conducted, varying the number of
holes to be drilled ranging from 50 to 7000 holes.
Detailed studies were done in terms of the friction and
the progressive wear while the response parameters were
mainly the chip morphology and the flank wear [62].
Designing of the drill in a very careful manner so as
not to disturb the flow of the mist formed during
MQL is another point of high importance. Also, it can
945
be concluded that the MQL process when used along
with a proper coated tool may give results nearly as
good as the flood cooling, and thus could act as a good
alternative for the expensive flood cooling approach.
Investigations were carried out on various methods of
external cutting fluid during blind-hole drilling of cast
aluminum alloy. The objective was to get an overall view
of the relative benefits of each with regard to dimen-
sional accuracy and operator’s exposure to hazardous
aerosols. The dimensional accuracy under dry cutting
conditions was found inferior and independent of cut-
ting speed and feed within the test range. For the
remaining cutting fluid application conditions, the most
dominant effects were those of cutting speed on hole
size. Flood cooling with synthetic cutting fluid was
found to be the best method for achieving both higher
hole accuracy and lower generated aerosol. In the case
of MQL cooling with soluble mineral oil, the oil content
of the cutting fluid hindered its cooling action while
providing limited lubrication. The high volume of fluid
used during flooding seems to absorb many of the parti-
culates generated during cutting, leading to a lower mist
concentration [63]. This study proved flood cooling as
a better method when compared to MQL techniques,
making it an even bigger challenge for the future
researchers to find out the optimal parameters while
using MQL, so as to give comparable results to flood
cooling. The water soluble coolant used may play an
important role in doing so. Kilickap et al. studied the
effects of different cutting parameters on performance
characteristics during the drilling of Al7075. They eval-
uated workpiece SR and the temperature changes due
to the heat at the cutting process. MQL, compressed
air, and dry processing (without the usage of any cooling
liquid) techniques were used. They found better results
with MQL technique than with other cooling techni-
ques. The best surface roughness was obtained at a cut-
ting speed of 20 m=min and 0.1 mm=rev as feed [64].
Another series of experiments were performed so as to
validate the usage of MQL while drilling deep holes in
cylindrical blocks of Al alloy instead of the traditional
method of using metal working fluids by flood cooling.
As a result of these experiments, a set of optimum values
of various parameters were obtained: cutting speed:
300 m=min, pressure: 6 bar, oil quantity: 80 mL=h, taper:
0.266 mm=10 mm length, feed: 0.8 mm=rev, point angle;
135 , while the temperature at the surface of the work-
piece was recorded as 32 [65]. Further, Tasdelen et al.
conducted drilling experiments using MQL by varying
certain conditions such as varying oil amounts, using
emulsions, and even using dry compressed air. Factors
such as TW, chip contact, SR etc. were taken as the
response parameters for the experimentation [66]. It
may be concluded that MQL has a potential to give
the best results in terms of SR as compared to the emul-
sion cooling methods. Dry compressed air leads to a bad
SR taking into account the deposition of the workpiece
material on the sides of the holes drilled and produced
longer chips as well. Dasch and Kurgin examined MQL
by varying the methods of mist application: external
 946 V. S. SHARMA ET AL.

TABLE 5.—Drilling of various materials under MQL.

References Work material Tool material Cutting parameters Cooling types used Type, conditions Parameters evaluated=DOE

Inconel
[59] Inconel 718 Coated carbide Vc: 30, 40, 50; External MQL T: Synthetic ester, palm oil; MH, subsurface
(AlTiN) fn: 0.05, 0.1; outlet air p: 2 bar; deformation, surface
WT: 20 lubricant q: 10.3 mL=h; damage, SR
outlet air q: 165 L=min
Titanium alloy
[61] Ti-6Al-4V AlTiN-coated Vc: 60, 80, 100 Dry, MQL T: Synthetic ester, palm oil; CF, torque, workpiece
indexable fn: 0.1, 0.2 outlet air p: 2 bar; temperature
carbide drill lubricant q: 10.3 mL=h;
outlet air q: 165 L=min
[60] Ti6Al4V Carbide drills, Vc: 10–50 Flood, MQL, external Flood: abundance of cutting Workpiece temperature
coated carbide advance and internal nozzle fluid with concentration of
f ¼ 0.1–0.2 mm emulsion above 3.5%
Aluminum
[64] Al7075 HSS tools Vc: 5, 10, 15, 20 MQL, compresses T: Boron oil–water mixture SR, temperature
fn: 0.1, 0.2, 0.3 air, dry air p: 10 bar
[65] Al alloy Drill variables Vc: 133, 200, 300 MQL p: 4.2, 5, 6; Workpiece surface
cylinder Point angle: 118, fn: 0.45, 0.6, 0.8 q: 20, 40, 80 temperature=ANOVA
126, 135 ;
Drill body taper
(mm=10 mm
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length): 0150,
0200, 0266
[63] Al alloy Uncoated solid Vc: 30, 60, 90 Dry, flood, MQL Flood: synthetic coolant, 5% Dimensional accuracy, air
(A390.0) carbide fn: 0.1, 0.3, 0.5 solution; soluble mineral oil, quality, TW, chip
DD: 10, L: 20, 30, 40 5% solution morphology
three-flute MQL: soluble oil 4V
concentrate flood 5 L=m
MQL q: 2, 30, 35
p: 6
[62] B 319 Al alloy Coated tungsten Vc: 160 MQL Coolant: misty blue canola oil Tool life, chip
carbide drills fn:.15 MQL: 25 mL=h morphology
L: 19 p:.68 m pa
Steel
[69] AISI-1040 High-speed steel n: 5, 11, 16 Dry, flood, MQL Flood q: 1.2 L=m Roundness deviation of
L: 19.5 MQL: air p: 6, air q: the holes is smaller using
90 mL=min (through nozzle MQL when compared
tip) to dry and wet
conditions.
[66] Precipitation- Carbide inserts Vc: 155 Dry, flood p: 6, 7 TW, chip contact,
hardened DD: 19 fn: 0.11 MQL (internal) q: 5, 15, 23 CF=torques SR
steel L: 33

Vc: cutting speed (m=min); fn: feed (mm=rev); fz: feed per tooth.

MQL, internal single channel, and internal double
channel MQL. The mist formed in each case was care-
fully examined, and values such as concentration and
the particle size of the mist were carefully calculated.
The results obtained were very much in competition with
the wet cooling systems [67]. External MQL can be
reported as the least expensive as well as the least com-
plicated method, although it showed a limitation of not
successfully drilling the deep holes. On the other hand,
the internal systems of mist application showed better
effictiveness in performing the desired operations ins pite
of being more complex to apply as compared to the
external MQL system. The major drawback recorded
was that the tool geometry, if not properly examined,
could lead to dissipation of the mist, thus making an
optimized tool design mandatory for successful appli-
catin of the cooling technique. Bhowmick et al. drilled
the Al alloy AM60 using both dry and MQL systems.
The main response parameters recorded were the drill
torque and the thrust forces, while cooling was done
using fatty acid-based or distilled water-based coolants
with a rate of application up to 10 mL=h. Dry machining
led to a very short TL as a result of magnesium depo-
sition and BUE formation, ultimately leading to failure
of the drill in as short as 80 holes. On the other hand,
MQL drilling resulted in parameters very much compa-
rable to those of flood cooling systems, giving a better
TL. The temperature of the workpiece was also close
to that of the flooding condition, thus making MQL
a highly desirable technique on account of its lesser cost
and environment friendliness [68]. Ahsan et al. carried
out drilling of steel with HSS tool and noted the hole
size produced under dry, flood, and MQL conditions.
They found roundness deviations were smaller under
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TABLE 6.—Grinding of various materials under MQL.

Refs. Work material Tool material Cutting parameters Cooling types used Type, conditions Parameters evaluated=DOE

Inconel
[72] Inconel 751 Resin bonded diamond TG: surface grinding (down MQL q: 60, 80, 100 GF, grinding temperature,
wheel; grinding) p: 2, 4, 6 SR
WD: 150; Vc: 2826; Vf: 0.9 m=min; Droplet diameter: 7, 12.9, 23.7 m
WW: 13 ae: 30 Velocity of droplet (m=s): 19.7, 25,
32
Titanium
[80] Ti-6Al-4V Al2O3 (91A46I8AV) TG: down grinding; Flood, MQL MQL SR, GF
titanium Vc: 900; T:Vegetable oil, synthetic oil,
alloy wc: 20, 30, 40; Behran cutting oil 34, Behran
ae: 2, 5,7 cutting oil 53
q: 20, 40, 50, 60, 70, 100, 140
p: 3,4, 5,6
Aluminum
[71] hardened One type of SiC; TG: Down wc surface Dry, flood, MQL Flood: water miscible SR &GF, surface
stainless five types of Al2O3 wheels grinding mode p: 1, q: 8.4 L=min, fluid velocity: morphology
steel (UNS Vc: 30 27 m=s
S34700); Al Vf: 1500 MQL q: 100 mL=h
alloy ae: 5, 15, 25, 35, 45, 55, 65 p: 4 bar
AA6061 SD: 100
SpDr: 15
Steel
[81] AISI 4340 Al2O3 grinding wheel Vc: 1980; Vf: 1; wc: 20; Flood, MQL Flood T: synthetic 5% Surface integrity (SR, MS,

947
ae: 40; ts: 12 s concentration; MH); grinding wheel
q: 11 L=min diametral wear
MQL T: vegetable oil;
35 mm part wheel interface
p: 5, 6 kgf=cm2
[77] AISI 4340 SNB151Q12VR2 (vitrified Vc: 1800; Vf:0.25, 0.50, 0.75 Flood, MQL, MQL with jet Cutting fluid:vegetable oil (semi) SR, acoustic emissions,
cubic boron nitride wheel) wc: 34.8; MQL cutting fluid: vegetable oil wheel wear
ae: 1.2  103; 2.5  103; (full bio)
3.7  103 mm=rev; Oil flow in MQL: 2.7  108 m3=s
ts: 3 s Air pressure in MQL: 6.0  105 Pa
Air flow: 8.0  103 m3=s
Velocity of compressed air in
cleaning system: 470 m=s
Air pressure in cleaning system
Workpiece: 7.0  105 Pa
[76] Quenched CBN grinding wheels Vc: 1800; Flood, MQL Flood T: vegetable oil emulsion GF, AE, SR, roundness
and Vf: 1 q: 20 L=min; flow velocity: 5.3 m=s errors, MH, RS,
annealed Workpiece n: 204 rpm; MQL T: Accu-Lube LB 1000 microstructural analysis
ABNT 4340 Penetration depth (a) of q: 40, 60, 80 mL=h
steel 0.1 mm; ts: 8;
Grinding width: 12 mm;
grinding cycles: 100;
Maximum cutting th.:
0.065 mm; Minimum cutting
thickness: 0.047 mm;

(Continued )
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TABLE 6.—Continued

Refs. Work material Tool material Cutting parameters Cooling types used Type, conditions Parameters evaluated=DOE

[74] EN8,M2, Alumina wheel Vc: 1500, 2700; Dry, flood, MQL Flood: a common emulsion of 5% Grind power, GF, grind
EN31 ae: 5, 15; by volume. temperature and
wc: 6.5, 15 p: 1; fluid velocity: 27 m=s workpiece SR=Taguchi
MQL T: pure synthetic oil castrol
p: 4; q: 33
[75] 100Cr6har- Vitrified bond corundum, GM: down cut Dry, flood, MQL MQL: mineral oil, fat alcohol, SR, GF
dened steel resin bond corundum and Vc: 1800; Vf: 3000 hydrocracked oil, ester, white oil,
vitrified bond SG wheels ae: 30 carbon hydride, water miscible
(based on high polymer
proportion), water soluble (based
on synthetic oil), MQL water
miscible (based on mineral oil),

948
pure water;
air p: 4; SD: 80; SpDr: 15
[73] Harden steel, Al2O3 (22A46I8V300) Vc: 1200, 1500, 1800; Dry, flood, MQL Flood: water-miscible coolant GF and surface quality
soft steel wc: 2.5, 5,10; lubricant Castrol Syntilo 2000,
ae: 5, 10, 15, 25 5% concentration on MQL

Vc: wheel velocity=speed m=min; wc: work speed m=min; Vf: work feed mm=min; ae: depth of cut in mm; ts: spark out time (s).
 A REVIEW ON MINIMUM QUANTITY LUBRICATION
MQL condition as compared to dry and wet conditions
[69]. A study by Tai demonstrated that the heat generation
through hole wall surface was significant in deep-hole
drilling of cast iron. It contributes to 24–66% of total
heat absorption in the workpiece based on the analysis.
The high air pressure could successfully suppress the
chip clogging-induced heat and enables stable deep-hole
drilling processes under MQL technology [70].
Drilling with MQL can be carried out externally only
in the cases where the surface quality of the holes can be
compromised, but for best results, the internally applied
MQL is the most suitable technique. Keeping the
environmental factor in view, the synthetic esters could
well be replaced by palm oil; thus the cost reduction
could be made possible as well while drilling inconel
and titanium alloys. Few researchers [63] pointed out
that during mist lubrication the mechanism at work
was cooling due to evaporation of the cutting fluid
rather than lubrication. They suggested the need for for-
mulating special cutting fluids for mist lubrication that
have a higher latent heat of vaporization. The high aero-
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sol concentration during mist lubrication points to the
need for a scientific assessment of the atomization
properties of cutting fluids. Furthermore, they need to
be formulated such that they atomize to a size range that
is nonhazardous to human health. Also in case of drill-
ing Al with over 2000 holes, diamond turned out to be
the best option with the highest tool life.
Likewise, during the machining of magnesium and its
alloys, MQL led to a lowered adhesion rate and BUE
formation, thus resulting in a better surface quality
and TL.
MACHINING USING MQL: GRINDING
A good amount of work has been done in the field of
grinding using MQL as shown in Table 6. In grinding
process, the abrasives plunge and slide against the work-
piece during material removal. This also results in a cut-
ting zone temperature as well as a high specific energy.
So in order to improve process efficiency, lubrication
becomes an important requirement for the grinding
fluids, along with chip removal and cooling the grinding
zone. These fluids tend to harm the environment as well
as the health of the operator. The cost factor also contri-
butes in a negative manner as the cost goes beyond feasi-
bility. Thus, MQL could serve as a good alternative for
these processes as compared to the conventional meth-
ods [71]. Inconel 751 has been studied for grinding by
Balan et al. so as to investigate the effect of the various
MQL parameters on grinding performance. It can be
interpreted that in comparison to the traditional meth-
ods, MQL can lead to a reduction in grinding force
(GF), SR, and the temperature. Furthermore, it may
also be reported that the MQL process is quantitatively
significant during grinding. It was possible to achieve
minimum GF and SR by increasing the amount of fluid
and air pressure in MQL. A rise in GF, temperature, and
roughness was observed with lower (2 bar) air pressure
[72]. The study is impeccable when considered in terms
949
of MQL parameters, but for accurate results, the factors
such as wheel velocity, work feed, and the depth of cut
should also be varied. Another study of steel grinding
the impact of the work hardness, feed, depth of cut,
and wheel speed on the surface properties was studied
in order to obtain optimum results for the performance.
It was observed that while grinding 100Cr6 hardened
steel using MQL, better surface finish was observed
along with improved quality. Conversely, while grinding
42CrMo4 soft steel, the results came out to be negative
in terms of surface roughness in comparison with flood
cooling [73]. When the critical cutting depth and lubri-
cation are increased, the chips formed may be of lower
thickness and the smaller grains, which lead to the gen-
eration of the uncut chips. But in case of 100Cr6 har-
dened steel, the formation of the chips takes place
through brittle fracture mechanism. MQL leads to a
lowered tangential force that in turn leads to better slip-
ping of the grains at the work–tool interface resulting in
a better surface finish and a reduced GF. A significant
difference was noted in case of MQL grinding, due to
the lubrication effect. Furthermore, the removal of the
metal took place due to shearing or fracturing, whereas
in case of the traditional methods, it occurred due to
shearing of fracture. The MQL flow rate may be varied
as well in order to find out the trend in the variations.
Barczak et al. examined three grades of steel—EN8,
M2, and EN31—for both MQL and the traditional
machining methods. They evaluated SR, GT, power,
and specific forces. It was concluded that MQL gave
results very much comparable to the flood cooling
method, although the cost factor was on the higher side
[74]. Efforts were made to find out the influence of the
different coolants as well as the grinding wheel materials
on the performance of the grinding process in terms of
the response parameters, GF, and SR. Many experi-
ments were preformed for MQL, dry, and flood cooling
methods in which 11 different kinds of coolants were
used while the wheel materials used were resin bond cor-
undum, vitrified bond corundum, and vitrified bond
[75]. The observations may be interpreted in the terms
that the SR wheels give the best possible results as com-
pared to the other variants. Furthermore, it did not
show any change in performance due to the change in
the wheel material and also reduced the chip loading
effect. Alves et al. studied the behavior of MQL for
developing methodology of fluid through the assembly
of special nozzle. MQL grinding of steel was performed
using pulverized vegetable oil in a compressed air flow.
They evaluated surface integrity and grinding wheel dia-
metrical wear. They got quite encouraging results for
surface integrity and TW with MQL. They obtained the
best performance of MQL at air (26.4 m=s) and lubricant
(40 mL=h) [76]. Another study investigated the grindability
of hardened stainless steel and aluminum alloy using dry,
MQL, and conventional fluid techniques. Five types of
corundum wheels and one type of SiC wheel were tested
along with vegetable and synthetic ester MQL oils. They
studied the effects of the wheel material and coolant types
in terms of factors such as GF, surface temperature, and
 950
surface topography. They found synthetic ester MQL oil
performed better as compared to the other vegetable-
based MQL oils [71]. When performing MQL cooling,
using soft wheels may give a better grindability. Grinding
Al-based alloys using vegetable oil-based MQL gives a
very low SR as compared to a very high surface rough-
ness when using ester-based additives, mainly due to
the chip loading effect on the grinding wheel. Oliviera
et al. performed MQL grinding of AISI 4340 tempered
and quenched steel using a vitrified CBN wheel. In
addition, an air jet focusing on the cutting zone was also
used that was helpful in cleaning the cutting zone by
removing the coolant as well as the chips. The analysis
was done on workpiece SR and roundness errors, dia-
metrical wheel wear, AE generated by the process, and
metallographic images of the ground surface and subsur-
face. Results showed the positive effects of implementing
the cleaning jet technique as a technological improve-
ment of MQL to reduce the consumption of cutting fluids
[77]. MQL process when used for grinding is successful
and even has the potential to surpass the conventional
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flooding methods. Due to a highly reasonable material
removal rate, lower friction leads to improved surface
properties while the TW tends to decrease. A properly
calculated selection of the cutting parameters tends to
make the machining process highly economical as com-
pared to the flooding or the dry cutting techniques. Press-
ure values ranging from 4 to 10 bars may be used for
better results.
CONCLUSIONS
MQL gave comparable results for turning, milling,
drilling, and grinding for all materials. Most of the
authors have showed a noticeable improvement in
performance with MQL machining compared to dry
machining, and more meaningful results could have
been obtained if it was also compared with flood
machining (few studies exist). It is found that MQL
contributes toward its usefulness by reducing the CT.
The dimensional accuracy=surface integrity of workpiece
improved mainly due to reduction of wear and damage
at the tool tip by the application of MQL. Therefore,
it is evident that MQL not only improves environment
friendliness but can also improve the machinability
characteristics. The machining parameters such as depth
of cut, cutting speed, etc. on interaction with the
large number of MQL parameters such as the type of
lubricant, count of nozzles, etc. tend to make it complex
to understand, and thus a better study of the interaction
of these factors is needed so as to make it easily under-
standable [78]. There are many ways by which MQL
can be studied and improved further and used to our
advantage. First of all, the chip evacuation system could
be used to improve its efficiency further. Also the further
studies on cooling techniques and tool materials could
lead to better results. Speaking of its economy point,
use of vegetable oils can make it highly economical
as compared to the other processes. Thus, considering
its economy and environment friendliness, it can be
V. S. SHARMA ET AL.
concluded that MQL is a possible alternative for the
conventional processes in the future machining operations.
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