Influence of nano-level variation of solid lubricant particle size in the machining of AISI 1040 steel

Significant advances have been made in understanding the behaviour of engineering materials when machining at higher cutting conditions from practical and theoretical standpoints. Nano-integrated manufacturing is a subject of immense interest for various sustainable engineered systems. Metal removal processes involves generation of high cutting forces and temperatures. Usage of proper lubricant is an important aspect to reduce forces and temperatures and as a whole to improve total cutting phenomena. The present investigation analyses a green, petroleum-free lubricant that is produced by mixing two environmentally benign components – canola oil and nano crystalline boric acid. To study the influence of variation of nano-level boric acid particle size and its weight percentage on the performance of proposed green particulate fluid lubricant (GPFL), various turning tests were conducted on AISI 1040 steel using tungsten carbide inserts. Variations in cutting forces, tool temperatures and surface roughness are studied. The experimental results reveal that increase of cutting forces as well as the tool temperatures with the decrease in the boric acid particle size. The surface quality of the machined surface is reduced as the solid lubricant particle size is reduced in the nano-level.