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The cutting fluid is significant in any metal cutting operation, for cooling the cutting tool and the surface of the workpiece, by lubricating the tool-workpiece interface and removing chips from the cutting zone. Recently, many researchers have been focusing on minimum quantity lubrication (MQL) among the numerous methods existing on the application of the coolant as it reduces the usage of coolant by spurting a mixture of compressed air and cutting fluid in an improved way instead of flood cooling. The MQL method has been demonstrated to be appropriate as it fulfills the necessities of ‘green’ machining. In the current study, firstly, various lubrication methods were introduced which are used in machining processes, and then, basic machining processes used in manufacturing industries such as grinding, milling, turning, and drilling have been discussed. The comprehensive review of various nanofluids (NFs) used as lubricants by different researchers for machining process is presented. Furthermore, some cases of utilizing NFs in machining operations have been reported briefly in a table. Based on the studies, it can be concluded that utilizing NFs as coolant and lubricant lead to lower tool temperature, tool wear, higher surface quality, and less environmental dangers. However, the high cost of nanoparticles, need for devices, clustering, and sediment are still challenges for the NF applications in metalworking operations. At last, the article identifies the opportunities for using NFs as lubricants in the future. It should be stated that this work offers a clear guideline for utilizing MQL and MQL-nanofluid approaches in machining processes. This guideline shows the physical, tribological, and heat transfer mechanisms associated with employing such cooling/lubrication approaches and their effects on different machining quality characteristics such as tool wear, surface integrity, and cutting forces.

Cutting fluid has cooling and lubricating properties and is an important part of the field of metal machining. Owing to harmful additives, base oils with poor biodegradability, defects in processing methods, and unreasonable emissions of waste cutting fluids, cutting fluids have serious pollution problems, which pose challenges to global carbon emissions laws and regulations. However, the current research on cutting fluid and its circulating purification technique lacks systematic review papers to provide scientific technical guidance for actual production. In this study, the key scientific issues in the research achievements of eco-friendly cutting fluid and waste fluid treatment are clarified. First, the preparation and mechanism of organic additives are summarized, and the influence of the physical and chemical properties of vegetable base oils on lubricating properties is analyzed. Then, the process characteristics of cutting fluid reduction supply methods are systematically evaluated. Second, the treatment of oil mist and miscellaneous oil, the removal mechanism and approach of microorganisms, and the design principles of integrated recycling equipment are outlined. The conclusion is concluded that the synergistic effect of organic additives, biodegradable vegetable base oils and recycling purification effectively reduces the environmental pollution of cutting fluids. Finally, in view of the limitations of the cutting fluid and its circulating purification technique, the prospects of amino acid additive development, self-adapting jet parameter supply system, matching mechanism between processing conditions and cutting fluid are put forward, which provides the basis and support for the engineering application and development of cutting fluid and its circulating purification.

Recently, the application of nano-cutting fluids has gained much attention in the machining of nickel-based super alloys due their good lubricating/cooling properties including thermal conductivity, viscosity, and tribological characteristics. In this study, a set of turning experiments on new nickel-based alloy i.e., Inconel-800 alloy, was performed to explore the characteristics of different nano-cutting fluids (aluminum oxide (Al2O3), molybdenum disulfide (MoS2), and graphite) under minimum quantity lubrication (MQL) conditions. The performance of each nano-cutting fluid was deliberated in terms of machining characteristics such as surface roughness, cutting forces, and tool wear. Further, the data generated through experiments were statistically examined through Box Cox transformation, normal probability plots, and analysis of variance (ANOVA) tests. Then, an in-depth analysis of each process parameter was conducted through line plots and the results were compared with the existing literature. In the end, the composite desirability approach (CDA) was successfully implemented to determine the ideal machining parameters under different nano-cutting cooling conditions. The results demonstrate that the MoS2 and graphite-based nanofluids give promising results at high cutting speed values, but the overall performance of graphite-based nanofluids is better in terms of good lubrication and cooling properties. It is worth mentioning that the presence of small quantities of graphite in vegetable oil significantly improves the machining characteristics of Inconel-800 alloy as compared with the two other nanofluids.

Sustainable metal machining always results in reduction in overall global environmental impacts such as material waste, power utility, and pollution, in machining industries. Even though there are several literature studies on eco-friendly cutting fluids, but they confine the applications to a single metal machining system only. Hence, this present work firstly prioritizes understanding of the role of various sustainable cutting fluids (viz. water-soluble oil, rice bran oil, coconut oil and neem oil) by analyzing the multi-response optimization (viz. application of VIKOR method) on lathe machine facing operation and thus exploring the optimal process variables. In addition, comparative study of the sustainable cutting fluids under consideration with their viscosities and wettability is added to enhance an in-depth comprehensive understanding of their role. Secondly , the estimated optimal eco-friendly cutting fluid (in this work, the neem oil) is adopted in two different machining systems such as computer numerical control (CNC) lathe system (3-axis facing) operations and a CNC turn-mill system (4-axis co-axial) operations for analyzing the machining responses with regard to their individual optimization and moreover, to correlate assessing of the machining parameters (viz. spindle speeds, tool feeds, and depth of cuts) on the generated responses using analysis of variance.

In most machining operations, cutting fluids are essential to ensure the economical profitability of the process. Turning of common plain carbon and low alloy steels is an example of manufacturing process widely used in several branches of the manufacturing industry, were the use of cutting fluids plays a key role in minimizing tool wear, machining forces and surface roughness, and improving overall process performance. Unfortunately, the cutting fluids, particularly those mineral-based, are considered harmful to the environment and therefore a source of pollution in production lines, as well as being a threat to the health of the operators. An attempt of minimizing environmental pollution is to use cutting fluids which are vegetable-based instead of mineral-based, with many producers offering this option in their portfolios. Doubts though arise on how vegetable-based cutting fluids perform compared with the mineral-based fluids. The present work compares the performance of three concentrations (3%, 7%, and 10%) of two vegetable-based cutting fluids (an emulsion and a synthetic) with one mineral-based fluid (semi-synthetic). The comparisons are made through reciprocating sliding tests, wettability, cooling capacity, viscosity, and cutting force measurement in turning of an AISI 1050 steel. All non-machining tests (friction coefficients, droplet contact angles (wettability), heat exchange coefficient by convection and viscosity) and machining tests (machining forces) were performed with all cutting fluids. This set of rheological and tribological tests performed allowed better understanding of the differences in machinability, regarding the cutting forces, of the cutting fluids evaluated. The results showed that, despite the better thermal and tribological properties of the mineral-based cutting fluids, the vegetable-based emulsion had an overall better performance in relation to the wettability angle and machining forces. These results, together with the greater sustainable appeal of vegetable-based cutting fluids, point to their clear feasibility in the machining of AISI 1050 steel.

Titanium alloys are the primary candidates in several applications due to its promising characteristics, such as high strength to weight ratio, high yield strength, and high wear resistance. Despite its superior performance, some inherent properties, such as low thermal conductivity and high chemical reactivity lead to poor machinability and result in premature tool failure. In order to overcome the heat dissipation challenge during machining of titanium alloys, nano-cutting fluids are utilized as they offer higher observed thermal conductivity values compared to the base oil. The objective of this work is to investigate the effects of multi-walled-carbon nanotubes (MWCNTs) cutting fluid during cutting of Ti-6Al-4V. The investigations are carried out to study the induced surface quality under different cutting design variables including cutting speed, feed rate, and added nano-additive percentage (wt%). The novelty here lies on enhancing the MQL heat capacity using nanotubes-based fluid in order to improve Ti-6Al-4V machinability. Analysis of variance (ANOVA) has been implemented to study the effects of the studied design variables on the machining performance. It was found that 4 wt% MWCNTs nano-fluid decreases the surface roughness by 38% compared to the tests performed without nano-additives, while 2 wt% MWCNTs nano-fluids improve the surface quality by 50%.

In the machining domain, the most undesired effect is the ‘friction’, which leads to excessive heat generation and results in wear of the cutting tool. Also, the effect of friction has a significant negative impact on the mechanical properties of the machined components. To address these negative consequences, a novel category of Cutting Fluids (CFs) has been invented. These CFs include nanoparticles (NPs) in the conventional CFs, resulting in the emergence of a new variant called Nano Cutting Fluids (NCFs). Conventional CFs are categorized as either mineral oil based or taking sustainability into account it may be also vegetable oil based. NCFs involve the incorporation of NPs into CFs and this innovation has gained significant recognition and is seen as a revolutionary solution in the field of machining. The implementation of NCFs in prominent machining operations such as turning, drilling, milling, and grinding has resulted in improved surface quality of machined parts and increased lifespan of cutting tools. This is achieved by reducing cutting forces, enhancing heat transfer, and minimizing friction at the cutting zone. Using NCFs in Minimum Quantity Lubrication enhances the machining process, promotes environmental friendliness, ensures sustainability, and effefctively tackles the environmental concerns associated with conventional CFs. This review provides a thorough analysis of recent research papers on the use of NCFs in machining processes. It discusses the limitations of NCFs and explores potential opportunities for sustainable and enhanced machining operations in the future.

This paper reviews recent progress and applications of usage of cutting fluids in conventional machining processes. In addition to reviewing the various conventional and advanced cooling techniques during machining, the paper also discusses the use of minimum quantity lubrication (MQL) in several types on metals such as steel, aluminum, alloy, and titanium alloys. Due to the toxicity of conventional cutting fluid resulting in ecological problems, the demand for environmentally friendly cutting fluid is rising. Therefore, natural vegetable oil is chosen as potential replacement as an environmentally friendly cutting fluid which fulfills the important aspects of biodegradability and sustainability. Application of vegetable oil-based cutting fluids under MQL techniques are also discussed. Moreover, the potential of palm oil as biodegradable and environmentally friendly natural vegetable oil-based metal-working fluids in MQL are reviewed.

In metalworking, cutting fluids play an important role by reducing heat and friction during machining, extending tool life, and improving surface finish. Although the positive effects of cutting fluid have been confirmed in many studies, the relevant cutting fluid parameters such as nozzle cross-section area and supply pressure, as well as their influence on the thermo-mechanical loads of the cutting tool, have been insufficiently investigated. This study investigates the effects of cutting fluid supply conditions on tool loads during continuous and interrupted orthogonal cutting processes. The research specifically addresses the impact of nozzle geometry and fluid jet orientation on the thermo-mechanical loads on the cutting tool, which have been underexplored in previous studies. A prototype tool holder, designed and additively manufactured for this purpose, allows for variations in nozzle geometry and jet orientation. Experiments were conducted under varying cutting parameters, nozzle geometries, and fluid pressures, with tool temperature being monitored through an embedded thermocouple. The results show that nozzle geometry significantly affects chip shape, which directly affects cooling efficiency and, consequently, tool temperature. The study also uses an inversely calibrated analytical model to analyze the tool temperature distribution, which shows that the highest temperatures occur in the tool-chip contact area, while temperatures outside this area decrease rapidly. In addition, the percentage of heat conducted into the tool decreases with increasing Péclet number, which is consistent in both continuous and interrupted cutting scenarios. These findings provide a deeper understanding of how cutting fluid nozzle design affects tool performance and establish a foundation for model-based temperature analysis in machining processes.

Surface roughness is considered as an important measuring parameter in the machining industry that aids in ensuring the quality of the finished product. In turning operations, the tool and workpiece contact develop friction and cause heat generation, which in turn affects the machined surface. The use of cutting fluid in the machining zone helps to minimize the heat generation. In this paper, minimum quantity lubrication is used in turning of AISI 304 steel for determining the surface roughness. The cutting fluid is enriched with alumina nanoparticles of two different average particle sizes of 30 and 40 nm. Among the input parameters chosen for investigation are cutting speed, depth of cut, feed rate, and nanoparticle concentration. The response surface approach is used in the design of the experiment (RSM). For the purpose of estimating the surface roughness and comparing the experimental value to the predicted values, three machine learning-based models, including linear regression (LR), random forest (RF), and support vector machine (SVM), are utilized in addition. For the purpose of evaluating the accuracy of the predicted values, the coefficient of determination (R2), mean absolute percentage error (MAPE), and mean square error (MSE) were all used. Random forest outperformed the other two models in both the particle sizes of 30 and 40 nm, with R-squared of 0.8176 and 0.7231, respectively. Thus, this study provides a novel approach in predicting the surface roughness by varying the particle size in the cutting fluid using machine learning, which can save time and wastage of material and energy.