Silver nanoparticle-based Tween 80 green cutting fluid (AgNP-GCF) assisted MQL machining - An attempt towards eco-friendly machining

In modern research, the instigation of eco-friendly and sustainable manufacturing options have drawn a great attention and become a global interest. Thus, usage of environmental pleasant cutting fluids and their least consumption in machining operation is a promising attempt towards cleaner and sustainable machining. In this work, experimental investigations during silver nanoparticle-based Tween 80 green cutting fluid (AgNP-GCF) assisted minimum quantity lubrication (MQL) machining were conducted. In the first stage of the work, synthesis and characterization of AgNPs was carried out. Secondly, novel AgNP-GCF has been developed by dispersing AgNPs in different proportions (0.2 wt %, 0.4 wt %, 0.6 wt % and 0.8 wt %) in the water based Tween 80 emulsifier oil. Lastly, the process performance of developed AgNP-GCF under different cutting speeds was investigated during MQL machining of Inconel 718. Process performance with regard to surface finish quality (surface roughness) of the machined workpiece material in five different machining environments such as dry machining (without cutting fluid), MQL machining with Tween 80 based cutting fluid (without AgNPs), MQL machining with 0.2 wt % AgNP-GCF, MQL machining with 0.4 wt % AgNP-GCF and MQL machining with 0.6 wt % AgNP-GCF was examined and results were related with each other. The substantial improvement in quality of machined workpiece material was observed during AgNP-GCF assisted MQL machining. Under tested cutting speeds, the 0.6 wt % AgNP-GCF assisted MQL machining was 55% more effective in reducing surface roughness when compared to dry machining and 26% more effective when compared to MQL machining with Tween 80 based cutting fluid (without AgNPs). The high quality of machined surface during MQL machining with AgNP-GCF was due to appreciable heat transfer through AgNPs and their strong inherent lubricant properties. This study is expected to promote the cleaner and more competent MQL machining through the application of developed eco-friendly cutting fluid.