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Lubricants
Special Issues
Advances in Sustainable Machining
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Advances in Sustainable Machining

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (15 July 2023) | Viewed by 8704

Special Issue Editor

Dr. Kishor Kumar Gajrani

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Indian Institute of Information Technology, Design and Manufacturing, Kancheepuram, Chennai 600127, India
Interests: smart manufacturing and industry 4.0; green and sustainable machining processes; advanced machining processes; micromanufacturing processes; nano and bio-tribology; green lubricants and coolants; coatings

Special Issue Information

Dear Colleagues,

Humans impact on the environment in numerous ways. Human civilization requires a healthy environment to ensure the survival of life on our planet. An effective balance between the environment and technology is pressing the need of today’s world. Technology has made our lives more comfortable, but our environment is paying a high price. Nowadays, it is fully understood how necessary a healthy environment is, both for humans and the survival of life on this planet. Therefore, efforts are increasing towards the adaptation of green and sustainable technology to reduce detrimental environmental impact.

Sustainable machining and manufacturing processes are desperately required. Among various manufacturing processes, machining is one of the most widely used. Hence, it must be made sustainable. The indirect impact of machining, due to its effect on surface integrity, and hence on product life, is even greater. Moreover, as economic factors induce shorter product cycles, and more flexible manufacturing systems, the importance of machining is expected to increase even further.

In traditional machining operations, a major environmental issue is the abundant, and often indiscriminate use of metalworking fluids (MWFs). The problems associated with conventional flood cooling are the indiscriminate use of cutting fluids, subsequent surface integrity and product life, operator health, machining cost, energy consumption and chip recyclability. However, sustainable machining leads to improved environmental friendliness, reduced cost, reduced power consumption, reduced wastes, enhanced operational safety, and improved personnel health. Among sustainable machining methods, dry cutting appears to be the most sustainable alternative to present methods for avoiding the undesired effects of MWFs. Minimum quantity lubrication is used where dry manufacturing is not feasible and/or flood cooling becomes undesirable. Cryogenic cooling is a good candidate to replace conventional cooling/lubricating methods as it provides improved environmental effects and no adverse health effects.

This research topic on “Advances in Sustainable Machining” has been launched to spotlight recent developments associated with dry cutting, minimum quantity lubrication, cryogenic cooling, and their hybrids, as well as their effects on the economy, environment and society. Furthermore, this collection aims to discuss the advantages and disadvantages of sustainable machining methods, ultimately investigating and examining their feasibilities.

We invite researchers to submit original research and review studies that deal with, but are not limited to, the following topics:

  • Dry cutting
  • Textured cutting tools
  • Minimum quantity lubrication (MQL)
  • Cryogenic cooling
  • Application of nanofluids and ionic liquid-based lubricants in machining
  • Carbon emissions during machining
  • Cost estimations for machining
  • Life cycle analysis of machining and lubricants
  • Tribology of machining
  • Friction and wear of cutting tools

Dr. Kishor Kumar Gajrani
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • dry cutting
  • minimum quantity lubrication
  • cryogenic cooling
  • vegetable fluids
  • nanofluids
  • ionic liquid-based lubricants
  • carbon emissions
  • machining cost
  • tribology of machining

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (4 papers)

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Research

15 pages, 11012 KiB  
Article
Machining Temperature, Surface Integrity and Burr Size Investigation during Coolant-Free Hole Milling in Ti6Al4V Titanium Alloy
by Ragavanantham Shanmugam, Satish Shenoy Baloor, Ugur Koklu, Ashwin Polishetty and Gururaj Bolar
Lubricants 2023, 11(8), 349; https://doi.org/10.3390/lubricants11080349 - 15 Aug 2023
Cited by 8 | Viewed by 1519
Abstract
Modern Aircraft structures use titanium alloys where the processing of holes becomes essential to assemble aerospace parts. Considering the limitations of drilling, the study evaluates the helical milling for hole processing in Ti6Al4V. The experimental evaluation was conducted by considering burr size, surface [...] Read more.
Modern Aircraft structures use titanium alloys where the processing of holes becomes essential to assemble aerospace parts. Considering the limitations of drilling, the study evaluates the helical milling for hole processing in Ti6Al4V. The experimental evaluation was conducted by considering burr size, surface roughness, machining temperature, and microhardness under coolant-free conditions. The axial feed and cutting speed were varied at three levels, and nine experiments were conducted. The results exhibit a lower machining temperature during helical milling than during drilling. In addition, the helical milling helped to lower the surface roughness and size of the exit burrs. However, helical-milled holes showed higher subsurface microhardness than conventionally drilled holes. The process variables were influential on machining temperature magnitude. The highest recorded temperature of 234.7 °C was observed at 60 m/min of cutting speed and 0.6 mm/rev feed. However, the temperature rise did not affect the microhardness. Strain hardening associated with mechanical deformation was the primary mechanism driving the increase in microhardness. Helical-milled holes exhibited an excellent surface finish at lower axial feeds, while chatter due to tool deformation at higher feeds (0.6 mm/rev) diminished the surface finish. The surface roughness increased by 98% when the cutting speed increased to 60 m/min from 20 m/min, while a moderate increment of 28% was observed when the axial feed increased to 0.6 mm/rev from 0.2 mm/rev. Furthermore, the formation of relatively smaller burrs was noted due to significantly lower thrust load and temperature produced during helical milling. Full article
(This article belongs to the Special Issue Advances in Sustainable Machining)
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18 pages, 21351 KiB  
Article
Understanding the Machinability and Energy Consumption of Al-Based Hybrid Composites under Sustainable Conditions
by Serhat Şap
Lubricants 2023, 11(3), 111; https://doi.org/10.3390/lubricants11030111 - 3 Mar 2023
Cited by 14 | Viewed by 1459
Abstract
Tribological properties are directly related to cutting efficiency. To achieve high machinability performances, sustainable coolants (minimum quantity lubricant (MQL), cryogenic etc.) have been used instead of conventional cutting fluids in recent years. This study used MQL and cryogenic-cooling techniques while milling Al-based hybrid [...] Read more.
Tribological properties are directly related to cutting efficiency. To achieve high machinability performances, sustainable coolants (minimum quantity lubricant (MQL), cryogenic etc.) have been used instead of conventional cutting fluids in recent years. This study used MQL and cryogenic-cooling techniques while milling Al-based hybrid composites. The effects of different cutting environments on flank wear, surface roughness, cutting temperature, and energy consumption were analyzed according to the Taguchi method. According to the findings, the best cutting environment for surface roughness, flank wear, and cutting temperature is the cryo-LN2-assisted cooling technique. In terms of energy consumption, MQL was found to be more efficient than cryo-LN2 and dry environments. According to SEM/EDS analysis, BUE formation was observed at the tool edges during milling in dry conditions. It was determined that cutting tool surfaces are smoother in MQL and cryo-LN2 environments. The effect ratios of control factors on response parameters were determined according to Taguchi analysis. As a result, it was concluded that MQL and cryo-LN2 strategies could be evaluated within the scope of sustainable conditions. Full article
(This article belongs to the Special Issue Advances in Sustainable Machining)
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12 pages, 2344 KiB  
Article
Analysis of Changes in Soot Content in Engine Oils under Operating Conditions
by Grzegorz Zając, Wojciech Gołębiowski, Małgorzata Szczepanik, Artur Wolak and Marie Sejkorová
Lubricants 2023, 11(2), 89; https://doi.org/10.3390/lubricants11020089 - 18 Feb 2023
Cited by 2 | Viewed by 2456
Abstract
Oil has an enormous influence on the condition of the engine. Determining its degradation allows companies to maximize the availability of a specific vehicle and fleet of vehicles in general. In the evolution of engine oil degradation, one of the variables considered to [...] Read more.
Oil has an enormous influence on the condition of the engine. Determining its degradation allows companies to maximize the availability of a specific vehicle and fleet of vehicles in general. In the evolution of engine oil degradation, one of the variables considered to be the most important is soot content. This article examines the direction and severity of soot content and dispersion changes in engine oil occurring during actual engine operation during four complete change intervals. The oil under study was operated in a city bus. It belonged to the fleet of vehicles of a transport company from new to the mileage of about 200,000 km. Soot content was determined in accordance with ASTM E2412-10, while dispersion size was determined using the dried drop test in accordance with ASTM D7899. The results obtained provide the basis for the conclusion that the direction of change in soot content in each interval is characterized by a high degree of homogeneity. With respect to the degree of soot build-up, a high level of similarity was observed between the intervals studied. The study of change in the degree of oil dispersion using the “drop on blotter” method made it possible to confirm the trend of decreasing dispersion as the run increases. The obtained results led to the development of a statistical model describing these relationships. Full article
(This article belongs to the Special Issue Advances in Sustainable Machining)
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Graphical abstract

20 pages, 20050 KiB  
Article
Investigation on Surface Integrity in Hard Turning of AISI 4140 Steel with SPPP-AlTiSiN Coated Carbide Insert under Nano-MQL
by Smita Padhan, Naresh Kumar Wagri, Lalatendu Dash, Anshuman Das, Sudhansu Ranjan Das, Mohammad Rafighi and Priyaranjan Sharma
Lubricants 2023, 11(2), 49; https://doi.org/10.3390/lubricants11020049 - 30 Jan 2023
Cited by 19 | Viewed by 2504
Abstract
The machined surface integrity in the turning of hardened steels is adversely influenced by heat generation and friction which requires pacification of the temperature by the effective cooling-lubrication approach and cutting tool performance. The present research analyzes the surface integrity of hardened AISI [...] Read more.
The machined surface integrity in the turning of hardened steels is adversely influenced by heat generation and friction which requires pacification of the temperature by the effective cooling-lubrication approach and cutting tool performance. The present research analyzes the surface integrity of hardened AISI 4140 steel during turning with recently developed scalable pulsed power plasma SPPP-AlTiSiN coated carbide tool under nanofluid-assisted minimum quantity lubrication (MQL). Zinc oxide nanoparticles and environmentally friendly radiator coolant are mixed to prepare the nano cutting fluid. This analysis addresses the various aspects of surface integrity concerning surface morphology, machined surface hardness, residual stress and white layer development, and machined surface finish under varying cutting parameters (depth of cut, speed, feed, nose radius). Response surface methodology (RSM) is suggested to predict and to optimize the surface roughness in hard turning. Thereafter, the predictive modelling and optimization results are implemented for economic analysis. According to the findings of the experiments, with a contribution of 58.18%, the feed rate possesses a high impact on the surface finish, followed by the nose radius (12.32%) and speed (0.85%). Consequently, the machined surface quality improved with the increase of the nose radius because of the minimum tool wear and due to the increase of the effective length of the cutting edge. At optimum cutting conditions, the tool life of SPPP-AlTiSiN coated carbide insert is noted as 46 minutes under nanofluid-MQL and consequently, it estimated the overall machining cost per component as Rs.23.12 in Indian currency. Full article
(This article belongs to the Special Issue Advances in Sustainable Machining)
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