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A REPORT ON

“Effects of Minimum Quantity Lubrication (MQL) in machining processes"

By
Kumud Malik 2021ABPS2259P
Akshat Jain 2021ABPS2725P

To
Dr. Anuj Sharma
Assistant Professor Department of Mechanical Engineering

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

PILANI (MARCH, 2024)
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Table of Content

❖ 1. Introduction
● About the topic………………………………………………………………….………3
● Applications……………………………………………………………………………..4
● Importance of this research topic……………………………………………………..4
● Issues which need to be resolved…………………………………………………….4
❖ Study 1:
● Objectives………………………………………………………………………………..5
● Methodology……………………………………………………………………………..5
● Observations…………………………………………………………………………….5
● Results……………………………………………………………………………………6
● Suggestions……………………………………………………………………………...6
● Research Gaps after the Literature Survey…………………………………………..6
❖ Study 2:
● Objectives………………………………………………………………………………..7
● Methodology……………………………………………………………………………..7
● Observations…………………………………………………………………………….7
● Results…………………………………………………………………………………..8
● Suggestions…………………………………………………………………………….9
● Research Gaps after the Literature Survey…………………………………………9
❖ Study 3:
● Objectives………………………………………………………………………………10
● Methodology……………………………………………………………………………10
● Observations……………………………………………………………………………10
● Results………………………………………………………………………………….11
● Suggestions…………………………………………………………………………….12
● Research Gaps after the Literature Survey…………………………………………12
❖ Study 4:
● Objectives………………………………………………………………………………13
● Methodology……………………………………………………………………………14
● Observations……………………………………………………………………………14
● Results…………………………………………………………………………………14
● Suggestions…………………………………………………………………………….15
● Research Gaps after the Literature Survey…………………………………………15
❖ References…………………………………………………………………………….16
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1. Introduction
The machining industry is going through an important time. People are really concentrating on
making things faster, more eco-friendly, and better. One idea that seems really good among all
the different ideas being looked at is called Minimum Quantity Lubrication (MQL). This is a way
of using just a little bit of oil or lubricant to make machines work better. This introduction talks
about the basics of MQL, why it's important, and some things we still need to figure out about it.

1.1 About the Topic

MQL is a big change in how we lubricate machines during machining. Before, we used a lot of
oil, either flooding the area or using neat oil systems. While these methods are good at reducing
friction and heat, they have some problems. They harm the environment, can be dangerous to
people's health, and cost a lot because of buying, getting rid of, and maintaining the oil.

On the other hand, MQL uses just a tiny bit of lubricant, usually as a fine mist or spray, directly
where the cutting is happening. This way has many benefits compared to the old methods. It
cuts down a lot on how much lubricant we use, which is better for the environment, safer for
workers, and cheaper to run. Also, MQL has been proven to make machining better by reducing
tool wear, making surfaces smoother, and making machining faster.

1.2 State of Art

Research into MQL's efficacy and applicability has gained momentum in recent years, with
numerous studies exploring its effects on various machining processes. Experimental
investigations have been conducted to assess the influence of MQL parameters such as flow
rate, nozzle distance, and lubricant type on machining performance. Simulation studies,
employing computational fluid dynamics (CFD) or finite element analysis (FEA), have provided
insights into fluid distribution, heat transfer, and chip formation during MQL-assisted machining.
Recent advancements in MQL technology have further expanded its scope of application.
Integration with advanced machining techniques such as high-speed machining, hard
machining, and dry machining has demonstrated MQL's versatility and effectiveness across a
wide range of materials and cutting conditions. Moreover, developments in lubricant
formulations and delivery systems have enhanced MQL's performance and reliability in
demanding machining environments.

1.3 Applications
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MQL finds applications across various machining processes, including milling, turning, drilling,
and grinding. In milling operations, MQL has been utilized to machine a diverse range of
materials, from aluminum alloys to hardened steels, with significant improvements in tool life
and surface quality. In turning applications, MQL has shown promise in reducing built-up edge
formation, improving dimensional accuracy, and extending tool longevity.
Similarly, MQL has been adopted in drilling operations to minimize chip welding, reduce burr
formation, and enhance hole quality, particularly in challenging materials such as titanium alloys
and stainless steels. In grinding processes, MQL has been employed to cool the grinding zone,
lubricate the wheel-workpiece interface, and flush away grinding debris, leading to improved
surface integrity and reduced thermal damage.

1.4 Importance of this Research Topic

Researching the effects of MQL in machining processes is incredibly important. In today's world,
where taking care of the environment and using resources wisely are major concerns, MQL
offers a great way to make machining more eco-friendly. By using just the right amount of
lubricant and making less waste, MQL fits well with the push for greener manufacturing.

Moreover, MQL can make machining more efficient and competitive. It helps reduce how much
the tools wear out, makes surfaces smoother, and makes tools last longer. This means
companies can make more things in less time and at a lower cost. This makes the industry more
competitive globally and helps the economy grow.

1.5 Issues which need to be Resolved

Despite the promising advantages of MQL, there are still some challenges and issues that need
to be dealt with. Firstly, there aren't standardized rules for using MQL, so its performance can
vary a lot in different machining situations. Also, the best settings for MQL can change based on
things like what material is being cut, how the cutting is being done, and what kind of machine is
being used. This means more research is needed to figure out the best ways to use MQL.

Moreover, we need to look into what happens in the long term when using MQL, especially how
it affects the life of tools and how well the machines work. While short-term studies have shown
that MQL is helpful right away, we need to do studies that look at its effects over a long period of
time to see if it keeps being helpful and reliable during lots of machining. Additionally, we need
to make sure that MQL works well with different kinds of lubricants, doesn't leave too much gunk
behind, and is easy to keep working smoothly in machines. These things need to be sorted out
so that MQL can be smoothly added to the ways we already do machining.
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Study 1 : Effects of Minimum Quantity

Lubrication (MQL) in machining processes using
conventional and nanofluid based cutting fluids

Objectives:

The research paper embarks on a meticulous investigation into the realm of Minimum Quantity
Lubrication (MQL) within the context of metal cutting operations. It is positioned against the
backdrop of traditional lubrication methods that are increasingly being scrutinized for their
environmental and health impacts. The objective stretches beyond the mere comparison of
MQL with conventional lubrication techniques; it aspires to establish MQL not only as a viable
alternative but as a superior method that harmonizes machining efficiency with environmental
stewardship. The study meticulously charts the course for evaluating the effectiveness of MQL
across various machining operations—drilling, turning, milling, and grinding—with a clear aim to
endorse sustainable manufacturing practices without compromising on performance
benchmarks.

Methodology:

The methodological framework adopted in the study is robust and comprehensive, involving a
critical review and synthesis of existing literature pertinent to the use of MQL in machining
processes. This extensive literature survey meticulously examines empirical studies, focusing
on parameters such as tool wear, surface finish, cutting forces, temperature regulation at the
cutting zone, and frictional aspects under the influence of MQL. The study goes further to
categorize the cutting fluids used in MQL into mineral oils, vegetable oils, and nanofluids, each
assessed for their performance and environmental impacts. This methodological approach not
only ensures a holistic understanding of MQL's benefits but also provides a structured pathway
to compare these benefits against traditional flood lubrication methods.

Observations:

The observations from this comprehensive study reveal significant insights into the operational
efficacy of MQL. It is observed that MQL considerably enhances machining performance by
optimizing critical parameters such as surface integrity, cutting force dynamics, thermal
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management in the cutting zone, and tool longevity. An interesting observation is the role of
MQL in significantly diminishing the friction coefficient at the tool-workpiece interface, which
inherently translates to reduced energy consumption and operational efficiency. Moreover, the
study observes a notable improvement in machining performance with minimal environmental
footprint when using vegetable oil-based and nanofluid-based cutting fluids under MQL, marking
a significant stride towards 'green' manufacturing practices.

Results:

The culmination of this investigation presents a compelling case for MQL as a transformative
approach in machining operations. The results unequivocally highlight the superiority of MQL
over conventional flood lubrication techniques by demonstrating its capacity to achieve, and in
certain instances surpass, the machining efficiency and surface quality associated with
traditional methods. These findings are pivotal, showcasing MQL's dual benefit of environmental
sustainability coupled with operational efficiency, thereby propelling it to the forefront as a
preferred lubrication method in modern manufacturing settings.

Suggestions:

Drawing from the compelling evidence presented, the study strongly advocates for the
widespread adoption of MQL across the manufacturing industry. It suggests an exploration into
optimizing the operational parameters of MQL, such as the type of cutting fluid, its flow rate, and
air pressure, to maximize the potential benefits. Furthermore, there is a call to action for the
development and testing of new, environmentally friendly cutting fluid formulations that could
enhance the effectiveness of MQL. The paper suggests that such advancements could solidify
MQL's position as a cornerstone of sustainable manufacturing practices.

Research Gaps after the Literature Survey:

Despite the thorough examination and positive outcomes presented in the paper, it
acknowledges certain gaps in research. It highlights the absence of long-term studies on how
MQL affects the lifespan of machine tools and its compatibility with various machining materials.
Additionally, there's a need for standardized methods to evaluate the environmental impacts of
MQL systems comprehensively. The paper also suggests that future research should explore
combining MQL with other advanced machining technologies like cryogenic cooling and
ultrasonic-assisted machining to maximize its benefits.

In summary, this research paper provides a comprehensive analysis that not only confirms the
effectiveness of MQL in improving machining but also positions it as a viable solution for
sustainable manufacturing. By thoroughly examining objectives, methodology, observations,
results, and recommendations, the paper lays out a roadmap for future research and application
of MQL, making a significant contribution to the field of sustainable manufacturing.
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Study 2: A study of plane surface grinding under

minimum quantity lubrication (MQL) conditions

Objectives:

The primary objective is to assess the performance of MQL in fine grinding operations,
comparing it against conventional flood cooling and dry grinding. The research seeks to
evaluate various performance indicators such as grind power, specific forces, grinding
temperature, surface roughness, and the real depth of cut across different steel materials (EN8,
M2, EN31) using a general-purpose alumina wheel. The study aims to determine if MQL can
deliver comparable or superior outcomes to flood cooling, thereby establishing its viability as a
sustainable grinding solution.

Methodology:

The study's methodology is structured around an experimental comparison of three different

lubrication conditions: wet (conventional flood cooling), dry, and minimum quantity lubrication
(MQL) in the plane surface grinding of common steel materials (EN8, M2, and EN31) using a
general-purpose alumina grinding wheel. The experiments were conducted on a Dominator 624
CNC surface grinding machine equipped with a state-of-the-art 3-component dynamometer to
accurately measure the tangential and normal forces exerted during grinding. Additionally, a
precision thermocouple was employed to monitor the temperature in the grinding zone, ensuring
the capture of comprehensive thermal data throughout the grinding process.

A key aspect of the methodology involved the use of the Taguchi design of experiments, which
facilitated a systematic exploration of a wide range of grinding conditions while minimizing the
number of trials required. This approach allowed for an efficient assessment of the influence of
various process parameters, including wheel speed, workpiece speed, depth of cut, and the
type of cooling/lubrication method, on the performance outcomes of the grinding process.

To ensure the reliability and accuracy of the experimental results, each grinding trial was
repeated three times under identical settings, with the mean values of the measurements being
used for subsequent analysis. The experimental setup was meticulously calibrated before each
trial, with particular attention paid to the dressing of the grinding wheel to achieve a consistent
and controlled grinding environment.

Observations:

The experimental trials yielded several key observations regarding the impact of lubrication
conditions on grinding performance:
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1. Specific Tangential Forces: Under MQL conditions, the specific tangential forces observed
were significantly lower than those recorded during dry grinding and, in some cases,
comparable to or better than those achieved with conventional flood cooling. This indicates that
MQL effectively reduces friction at the grinding interface, contributing to more efficient material
removal.

2. Surface Roughness: The surface finish of workpieces ground under MQL conditions
consistently met the expected quality standards for precision grinding operations. In several
instances, MQL even outperformed flood cooling in achieving superior surface finishes,
suggesting that the aerosol-based delivery of lubricant improves the interaction between the
grinding wheel and the workpiece surface.

3. Temperature Control: Temperature measurements revealed that MQL offers effective thermal
management during grinding, preventing excessive heat buildup and minimizing the risk of
thermal damage to the workpiece. The temperatures recorded under MQL were well within safe
limits, underscoring the method's suitability for maintaining part integrity.

4. Real Depth of Cut: The study also observed that the actual depth of cut achieved with MQL
closely matched the programmed values, indicating minimal wheel wear and loading. This
contrasts with dry grinding, where wheel loading can lead to discrepancies between
programmed and actual depths of cut.

Results:

The results of the experimental trials provide compelling evidence of the benefits of MQL in
plane surface grinding:

Grinding Efficiency: MQL was found to enhance grinding efficiency, as evidenced by reduced
specific tangential forces and improved material removal rates. This suggests that MQL not only
conserves lubricant but also optimizes the grinding process.

Surface Quality: Workpieces ground with MQL exhibited high-quality surface finishes, often
surpassing those achieved with conventional flood cooling. This highlights MQL's potential to
improve the quality of ground surfaces without compromising on environmental and health
safety.

Thermal Management: The effective temperature control observed under MQL conditions
underscores its capability to mitigate thermal risks in grinding, thereby preserving the
metallurgical and structural integrity of the workpiece.

Sustainability: By significantly reducing the volume of lubricant required, MQL offers a more
sustainable alternative to flood cooling, with potential reductions in operational costs and
environmental impact.
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Conclusions:

The study concludes that MQL is a viable and efficient lubrication method for plane surface
grinding, capable of delivering performance on par with or better than conventional flood
cooling. MQL offers significant advantages in terms of environmental impact, cost reduction, and
machining efficiency. The findings support the broader adoption of MQL in surface grinding
applications, particularly for materials that are not excessively hard.

Suggestions:

Based on the findings, the study recommends further exploration into optimizing the parameters
specific to MQL, such as fluid type, delivery rate, and aerosol distribution, to maximize its
benefits. It also suggests investigating the integration of MQL with other advanced cooling and
lubrication technologies to enhance its effectiveness further. The development of new, more
effective MQL fluid formulations could also contribute to improving grinding performance and
sustainability.

Research Gaps after the Literature Survey:

Despite the promising results, the study acknowledges several research gaps. There is a need
for more extensive research on the long-term effects of MQL on tool life and its effectiveness
across a broader range of materials and grinding operations. Additionally, the study identifies a
lack of comprehensive understanding of the mechanisms underlying MQL's performance
benefits, suggesting areas for future fundamental research. The environmental impacts of MQL,
particularly in terms of aerosol dispersion and operator exposure, also warrant further
investigation.

In conclusion, this research paper provides a thorough examination of MQL's potential to

revolutionize plane surface grinding by offering a sustainable alternative to conventional
lubrication methods. Through detailed analysis and experimentation, the study lays the
groundwork for future research aimed at unlocking the full potential of MQL in improving
grinding efficiency and environmental sustainability.
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Study 3 : Performance improvement of minimum

quantity lubrication (MQL) technique in surface
grinding by modeling and optimization

Objectives:

The primary objective of this research was to investigate the effectiveness of the Minimum
Quantity Lubrication (MQL) technique in grinding operations, focusing on its impact on
mechanical properties of the workpiece, especially hardness. The study aimed to compare the
performance of MQL against traditional dry grinding and conventional fluid cooling methods
across various steel materials, including both soft and hard steels. A key goal was to ascertain
whether MQL could reduce grinding forces and friction coefficient while enhancing surface finish
and quality, particularly in grinding hard steels, which have been less explored in the context of
MQL.

Methodology:

The study's experimental design aimed at investigating the impact of MQL on the grinding
process across different steel materials, including two soft steels (CK45 and S305) and two hard
steels (HSS and 100Cr6). The grinding operations were performed using a 2.5-axis CNC
surface grinder, employing an aluminum oxide grinding wheel. Three distinct lubrication
conditions were evaluated: dry, conventional fluid cooling, and MQL.

For the conventional fluid grinding, a water-based coolant-lubricant at 10% concentration was
utilized. The MQL setup featured a system that sprayed a small quantity of oil (Behran RS1642)
in a compressed air jet directly into the cutting zone, aiming to provide efficient lubrication with
significantly reduced fluid usage. The oil flow rate was set at 120 ml/h with an air pressure of 4
bars. Grinding forces were measured using a KISTLER 3-component dynamometer. To ensure
consistency across all tests, the grinding wheel was dressed before each experiment under
specified conditions.

The experiments were designed to measure several output parameters, including specific
normal and tangential grinding forces, friction coefficient, surface roughness, surface
morphology, and chip formation, under each lubrication condition. This comprehensive set of
measurements was intended to capture the nuances of the grinding process under varying
mechanical properties of the workpiece and lubrication conditions.

Observations:

The experimental observations revealed several critical insights into the grinding process under
different lubrication conditions:
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Grinding Forces and Friction Coefficient: MQL significantly reduced both the grinding forces and
friction coefficient across all tested materials, indicating its effectiveness in improving lubrication
at the cutting zone. This reduction was particularly notable in the soft steels, suggesting that
MQL might reduce power consumption and improve efficiency in grinding operations involving
softer materials.

Surface Roughness and Quality: The impact of MQL on surface roughness varied with the
hardness of the steel. For hard steels, MQL resulted in superior surface finishes compared to
dry and conventional fluid cooling methods. However, for soft steels, MQL did not perform as
well, with surface finishes being the worst among the tested lubrication conditions. This
discrepancy highlights the influence of material properties on the effectiveness of MQL.

Chip Formation: Observations of chip morphology indicated that MQL could influence the chip
removal mechanism, making it more akin to that seen in conventional fluid cooling. This
suggests that MQL might not only reduce lubricant usage but also potentially improve chip
management in grinding operations.

Results:

The study's results underscored the potential of MQL as a viable alternative to conventional fluid
cooling, particularly for grinding hard steel materials. MQL demonstrated the ability to
significantly reduce grinding forces and improve surface quality while minimizing the
environmental and health hazards associated with traditional metalworking fluids. However, the
performance of MQL in grinding soft steels was less favorable, highlighting a potential limitation
of this technique based on the material properties of the workpiece.

To address the challenge of optimizing surface roughness in soft steels when using MQL, the
study further explored modeling and optimization techniques. A second-order response surface
model based on the response surface method (RSM) was developed to predict surface
roughness under various cutting conditions. Optimization using the genetic algorithm (GA)
identified optimal grinding parameters that minimized surface roughness, demonstrating the
utility of these techniques in enhancing the application of MQL across a broader range of
materials.

In conclusion, the elaborate examination of the methodology, observations, and results from this
study presents a nuanced understanding of how MQL affects the grinding process. It highlights
the technique's advantages in certain conditions while also pointing out its limitations, guiding
future research towards optimising grinding parameters for different materials when employing
MQL.
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Suggestions:

Based on the findings, it is recommended to further explore the optimization of MQL

parameters, such as the type and flow rate of lubricant, to enhance its applicability across a
broader range of materials and grinding conditions. Additionally, the development of more
advanced MQL systems that can more effectively target the lubricant to the cutting zone could
further improve its performance, especially in grinding operations involving soft steels.

Research Gaps after the Literature Survey:

The exploration into the performance of the Minimum Quantity Lubrication (MQL) technique in
surface grinding operations, as highlighted by this study and existing literature, reveals
significant insights and advancements. However, it also uncovers several research gaps that
present opportunities for future investigation. These gaps are not merely unexplored territories
but areas where further research could significantly enhance the understanding and application
of MQL in grinding processes. Elaborately, the research gaps identified include:

1. Material Specific Performance: Existing studies, including this one, demonstrate that the
effectiveness of MQL varies significantly across different materials, particularly between soft and
hard steels. While there is some understanding of MQL's impact on various steels,
comprehensive studies focusing on a wider range of materials, including non-ferrous metals and
alloys, are limited. Future research could aim to establish a more detailed understanding of how
MQL performs across a broader spectrum of materials, potentially leading to the development of
material-specific MQL strategies.

2. Optimization of MQL Parameters: The optimization of MQL parameters (such as oil type, oil
flow rate, air pressure, and droplet size) for specific grinding operations has been explored to
some extent. However, there is a lack of a comprehensive framework that considers the
interplay between these parameters and the grinding conditions (e.g., wheel speed, feed rate,
depth of cut). Developing a more nuanced understanding of these relationships could
significantly improve MQL's effectiveness and efficiency.

3. Environmental and Health Impact: While MQL is touted for its reduced environmental and
health impact compared to traditional flood cooling, detailed studies quantifying these benefits
are sparse. Research that systematically evaluates the environmental footprint of MQL
(including the lifecycle impact of the lubricants used) and its effects on operator health and
safety could provide a stronger basis for its adoption.

4. Economic Analysis: Comprehensive economic analyses comparing MQL with traditional

lubrication methods are limited. Such studies should consider not only the direct costs
associated with lubricant consumption and disposal but also indirect costs related to tool wear,
workpiece quality, machine maintenance, and operator health. An in-depth economic analysis
could help quantify the total cost of ownership and operational savings associated with MQL.
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5. Integration with Advanced Manufacturing Techniques: As manufacturing processes become

increasingly sophisticated, integrating MQL with advanced manufacturing techniques (such as
high-speed machining, additive manufacturing, and hybrid processes) represents an
underexplored area of research. Investigating how MQL can be adapted or optimized for these
cutting-edge processes could open up new avenues for its application.

6. MQL in Grinding of Composite Materials: The application of MQL in the grinding of composite
materials (e.g., metal matrix composites, carbon fiber-reinforced polymers) has received limited
attention. Given the growing importance of composite materials in various industries, research
into the effectiveness of MQL in these contexts is urgently needed.

7. Long-term Performance and Sustainability: Longitudinal studies examining the long-term

performance of grinding machines and tools under MQL conditions are scarce. Research in this
area could provide valuable insights into the sustainability of MQL, including its impact on tool
life, maintenance requirements, and overall machine health.

Study 4: Evaluation of ionic liquids as lubricants

in micro milling - process capability and
sustainability

Objectives:

The primary objective of the research was to evaluate the performance of ionic liquids as
lubricants in the micro end milling process, with a particular focus on assessing their
sustainability and process capability. This objective was driven by the need to identify
eco-friendly alternatives to traditional cutting fluids, which pose environmental and health
hazards and are associated with high recycling costs. Ionic liquids, known for their low vapor
pressure, non-flammability, thermal stability, and high friction reduction capabilities, were
selected as potential candidates for this purpose.

The study aimed to investigate two specific types of ionic liquids—1-ethyl-3-methylimidazolium

bis(trifluoromethylsulfonyl)imide ([EMIM][TFSI]) and 1-butyl-3-methylimidazolium iodide
([BMIM][I])—and compare their performance against conventional oils, distilled water, and dry
machining conditions. The evaluation criteria included cutting forces, surface morphology, and
surface roughness of the machined workpieces, as well as the evaporation rate of the lubricants
during the machining process. Through this comprehensive assessment, the research sought to
determine the feasibility of using ionic liquids as sustainable and effective lubricants in micro
milling operations, potentially contributing to the advancement of green manufacturing practices.
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Methodology:

The study conducted a series of experiments to evaluate the effectiveness of ionic liquids as
lubricants in the micro end milling process, focusing on their sustainability and process
capability. Two types of ionic liquids were tested: 1-ethyl-3-methylimidazolium
bis(trifluoromethylsulfonyl)imide ([EMIM][TFSI]) and 1-butyl-3-methylimidazolium iodide
([BMIM][I]), alongside two conventional oils, distilled water, and dry conditions for comparison.
The experimentation was performed on aluminum Al 5052 workpieces using tungsten carbide
(WC) tools with a 200 mm diameter.

The experimental setup was designed to simulate a real micro milling environment, equipped
with a three-axis stage controlled by CNC programming, a dynamometer for cutting force
measurements, and a high-speed camera for recording the cutting process. For each test, a
small volume of the selected lubricant was applied to the workpiece, and a rectangular pocket
was milled to assess the performance of each lubricant based on cutting forces, surface
morphology, and roughness. Additionally, the sustainability of the lubricants was evaluated
through their evaporation rate during the machining process.

Observations:

During the experimentation, several observations were made regarding the behavior of the
chips, the visibility and retention of lubricants in the cutting zone, and the physical interaction
between the tool and workpiece under different lubrication conditions. Notably, the chips
produced in dry conditions were larger and more scattered compared to those produced under
lubricated conditions. Ionic liquids, particularly the high-viscosity [BMIM][I], were effective in
confining chips within the cutting zone, potentially due to their adhesive properties. The cutting
forces measured indicated that ionic liquids could perform comparably to or better than
conventional oils, with [BMIM][I] and one of the conventional oils resulting in the smoothest
machined surfaces.

Results:

The ionic liquids demonstrated significant promise as lubricants in micro milling, particularly in
terms of surface finish quality and sustainability. Specifically, [BMIM][I] yielded the lowest
surface roughness among all tested lubricants, suggesting its superior lubrication performance.
Both ionic liquids exhibited extremely low volatility, which underscores their sustainability
advantage over conventional oils, as they do not evaporate or decompose at room
temperatures, thereby reducing environmental and health hazards associated with traditional
machining fluids.
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Suggestions:

Given the positive outcomes associated with the use of ionic liquids in micro milling, it is
recommended that further research be conducted to explore their full potential across a wider
range of materials and machining operations. Additionally, there is a need to develop
comprehensive guidelines for the selection and application of ionic liquids in micro machining to
optimize their performance and sustainability benefits. Future work could also focus on
investigating the economic implications of transitioning to ionic liquids from conventional oils,
considering both operational costs and environmental impact.

Research Gaps after the Literature Survey

Despite the promising results, the study identified several research gaps that warrant further
investigation:

1. Comprehensive Analysis across Materials: While this study focused on aluminum Al 5052,
the performance of ionic liquids as lubricants should be tested on a broader spectrum of
materials, including harder metals and alloys, to fully understand their applicability and
limitations.

2. Long-term Impact on Tool Wear: The long-term effects of ionic liquids on tool wear and life
have not been fully explored. Understanding how these lubricants affect tool degradation over
time is crucial for their widespread adoption.

3. Health and Environmental Impacts: While ionic liquids are considered eco-friendly,
comprehensive studies assessing their long-term environmental and health impacts are
necessary, including potential toxicity and disposal issues.

4. Cost-Benefit Analysis: An in-depth economic analysis comparing the use of ionic liquids to
conventional lubricants is needed. Such a study should consider not only the direct costs
associated with lubricant purchase and disposal but also the potential savings from reduced tool
wear, lower health and safety risks, and environmental compliance costs.

5. Integration with Advanced Machining Techniques: The compatibility and performance of ionic
liquids in conjunction with advanced machining techniques, such as high-speed machining and
additive manufacturing, remain largely unexplored.

By addressing these gaps, future research can pave the way for the development of more
sustainable, efficient, and cost-effective machining processes, leveraging the unique properties
of ionic liquids.
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References

1) Effects of minimum quality lubrication in maching processes using

conventional and nanofluid based cutting fluids by Dr. Anuj Kumar Sharma,
Dr. arun Kumar Tiwari, Dr. Amit Rai Dixit.

2) A study of plane surface grinding under minimum quantity lubrication

(MQL) conditions by L.M Barczak, A.D.L Bataka and M.N Morgan.

3) Performance improvement of minimum quantity lubrication (MQL)

technique in surface grinding by modeling and optimization by F. Rabiei and
A.R. Rahimi.

4) Evaluation of ionic liquids as lubricants in micro milling – process capability

and sustainability by Minh-Quan Pham , Hae-Sung Yoon , Varsha Khare.