Study on the application of ionic liquids in bio-based lubricant for a sustainable machining process

Many factors tend to influence the increased demand in recent years, including stateof- the-art of effective and environmentally friendly metalworking fluids (MWFs). Bio-based lubricants from vegetable oils are highly biodegradable, non-toxic, pose good lubricating properties and low production costs. They have been widely perceived as a potential to reduce or replace the high dependency on the applications of petroleum-based MWFs. However, the inconsistent chemical composition and low thermal and oxidative stabilities of the natural oils leaves significant uncertainties about the overall sustainability performance of the bio-based MWFs. In this study, with the objective of achieving machining sustainability, a novel chemically modified Jatropha-based trimethylolpropane ester (MJO) was refined by mixing it with ionic liquids (ILs) additives. Two biocompatible and oil-miscible ILs; [P6,6,6,14][(iC8)2PO2] (PIL) and [N1,8,8,8][NTf2] (AIL) were mixed in the MJO at 1, 5, and 10 % weight concentrations. The newly refined mixtures are validated for their physicochemical and tribological properties as well as when being applied for minimum quantity lubrication (MQL) machining (orthogonal and oblique) of AISI 1045 steel. Results showed that, the lubrication performance of MJO+AIL10% and MJO+PIL1% outperformed the other lubricant samples used herein. With improved physicochemical and tribological performances, e.g. corrosion inhibition, friction and wear reduction, smooth surface finish and high machining efficiency, they recorded improvement in machining forces up to 12 %, cutting temperature up to 10 %, surface roughness by 7% and increased cutting tool life up to 50 % compared to the commercial synthetic ester-based MWF. A machining sustainability index evaluation was applied to the MQL machining scenario and based on results, MJO+PIL1% obtained the highest score for minimum lubricant’s cost, minimal energy consumption, or the best sustainability performance (4.08/5) and seconded by MJO+AIL10% (4.06). These novel bio-based MWFs provide another alternative to the world dominating mineral oil-based lubricants for “greener” and more sustainable working environment

Machining performance of vegetable oil with phosphonium- and ammonium-based ionic liquids via MQL technique

Thermo-mechanical loads are the main factor that influences the tool wear and product surfaces during machining processes. Lubrication in metal cutting is an effective medium to reduce frictional forces and wear on the tool-workpiece interfaces. On this regards, the advantages of using refined bio-based metalworking fluids (MWFs) with the presence of low toxic, biocompatible and oil-miscible ionic liquids (ILs) additives ([N1,8,8,8][NTf2] (AIL) & [P6,6,6,14][(iC8)2PO2] (PIL)) at nominal weight concentrations of 1, 5 and 10% are explored during orthogonal cutting of AISI 1045 steel. Accordingly, the lubricants are supplied via minimum quantity lubrication (MQL) technique and comparative studies are conducted against the performance of the neat modified Jatropha-based lubricant (MJO) and commercially available synthetic ester-based MQL cutting fluid (SE). The combination of mist supply of the MJOs during machining have a great impact on cleaner production that eliminates the excessive usage of fluids and supports the utilization of environmentally friendly chemicals. This work extends the application of a minute quantity of fully miscible ILs in polar vegetable-based MWF which proven to provide a significant improvement on the lubrication effect of the MJO. MJOþAIL10% and MJOþPIL1% showed the best cutting performance amongst all lubricant mixtures with reduction of cutting forces and specific cutting energy by 4 to 5%, cutting temperatures by 7 to 10%, friction coefficient by 2 to 3%, tool-chip contact length by 8 to 11%, chip thickness by 22 to 25%, friction angle by 1 to 2% and increased shear angle by 25 to 29% compared to the SE. Besides, the effect of low friction and reduced cutting forces produced lower specific cutting energy that promotes “greener” and more sustainable working environment

Tribological performance of modified jatropha oil containing oil-miscible ionic liquid, for machining applications

Modifying physicochemical and tribological properties of a bio-based lubricant is essential in improving its lubrication performances. This paper presents the effectiveness of a fully oil-miscible Ionic liquid (IL) as lubricant additive into a bio-based lubricant. Methyltrioctylammonium bis(trifluoromethylsulfonyl)imide (AIL) was selected as IL additive to improve the tribological performance of the bio- based lubricant. Additive was mixed into the bio-based lubricant at three levels of mass concentrations (1 wt.%, 5 wt.% & 10 wt.%). Tribology tests on steel/steel contacts were conducted to evaluate the lubricant samples. Test outputs were benchmarked against the neat bio-based lubricant. Results revealed good synergistic effect of the AIL additive blended into the bio-based lubricant. MJO+AIL10 % has shown good corrosion inhibition, superior friction reduction (48 %), lower worn surface area (23 %), excellent surface finish (46 %) and increased tapping torque efficiency (8 %). MJO+AIL10 % provided excellent tribological performances which corresponds to the energy saving and environmental benefit for sustainable machining applications

Tribological analyses of modified jatropha oil with hBN and graphene nanoparticles as an alternative lubricant for machining process

The increase of health and environmental consciousness has motivated the effort of technology improvement on lubrication by finding and exploring another potential alternative to replace mineral-based metalworking fluids. Due to this concern, vegetable-based oils have been recognised as an ideal lubricating base oil in machining due to low toxicity, biodegradable, and renewable energy sources. Moreover, nanofluids have attracted enormous attention in the field of lubrication due to excellent physical and chemical properties that can enhance tribological characterisation. The objective of the current work is to develop a new formulation of nanofluids in modified jatropha oil (MJO) by adding hexagonal boron nitride (hBN) and graphene nanoparticle additives at the lowest concentration (0.01, 0.025. and 0.05 wt. %). The physicochemical tests in terms of kinematic viscosity and viscosity index were conducted and compared with synthetic ester (SE). Tribology testing was conducted through four-ball test to determine the coefficient of friction, mean wear scar diameter, and friction torque. The result shows a significant improvement of MJO samples by adding nanoparticle additives compared to the SE. MJOg2 (MJO + 0.025 wt. % of graphene) exhibited excellent tribological behaviour by providing the lowest coefficient of friction and friction torque. Meanwhile, MJOh1 (MJO + 0.01 wt. % of hBN) provided with a smaller mean wear scar diameter among other lubricant samples. Conclusively, the addition of nanoparticle additives significantly enhanced the tribological characteristics and is highly suitable as a substitute for SE

Performance comparative of modified jatropha based nanofluids in orthogonal cutting process

As machining operation is getting crucial, thus nanotechnology has been considered in providing more effective performance to reduce friction coefficient and wear protection of both workpiece and tool. This study investigated effect of an inclusion of solid nanoparticle additives such hexagonal boron nitride (hBN), graphene, copper oxide (CuO) at 0.05 wt.% concentration in modified jatropha (MJO) based oil. The performance of nanofluids was evaluated by conducting friction and wear test via four-ball test as well as machining process through orthogonal cutting process. The attained results were then compared with synthetic ester. This present study revealed the MJO nanofluids (MJO + 0.05 wt.% hBN, MJO + 0.05 wt.% graphene and MJO + 0.05 wt.% CuO) showed higher lubrication performance as compared to the commercial synthetic ester in term of physical properties and tribological behaviour. This condition resulted in the excellent machining performance which was explained by the reduction in maximum cutting temperature, chip thickness, effect of morphology chip and tool-chip contact length. Therefore, the MJO nanofluids can be considered as a potential sustainable metalworking fluid to replace the usage of the currently used synthetic ester in machining operation

Modified Jatropha nano-lubricant as metalworking fluid for machining process

Biodegradable oils that were derived from the nature are renewable sources that may substitute the petroleumbased and synthetic oils. However, the highly viscous Jatropha oil draws upon unsatisfactory lubrication performance in the machining process. Thus, in this study, the chemically modified Jatropha oils with and without the hBN nanoparticles additive were tested on an orthogonal cutting process as a metalworking fluid. The oil viscosity, cutting force (Fc), cutting temperature (Tc) and tool-chip contact length (Lc) are the criteria being evaluated. The results show that MJO+0.05wt.% hBN posed high viscosity index which correlates with the low Fc, Tc and Lc. This increases its potential for implementation as a green metalworking fluid for a sustainable machining process

Tribological Interaction of Bio-Based Metalworking Fluids in Machining Process

Metalworking fluids were applied during the machining process to lubricate and cool the machine tool in order to reduce wear, friction, and heat generated. The increasing attention to the environment and health impacts leads to the formulation of eco-friendly metalworking fluids derived from vegetable oils (Jatropha and palm oils) to substitute the use of mineral-based oil. The present work focuses on the performance of refined bio-based metalworking fluids during tapping torque and orthogonal cutting processes. Bio-based metalworking fluids were formulated using 0.05 wt.% of hexagonal boron nitride (hBN) and 1 wt.% of phosphonium-based ionic liquid [P66614][(iC8)2PO2] in a modified Jatropha and palm olein oils and were examined for their rheological properties in comparison with a commercially obtained synthetic ester (SE)-based cutting fluid. The tapping torque performance of the refined bio-based metalworking fluids was evaluated for their torque and efficiency. In addition, the performance of these bio-based metalworking fluids on orthogonal cutting parameters such as cutting force, cutting temperature, chip thickness, tool-chip contact length, and specific cutting energy was highlighted. The results obtained revealed that the rheological properties of the newly formulated bio-based metalworking fluids were improved. From the tapping torque and orthogonal cutting performances, it was proven that the modified palm and Jatropha oils possess good anti-wear and anti-friction behavior compared to SE. In conclusion, the newly formulated bio-based metalworking fluids are suitable for the use as a new advanced renewable metalworking fluid for machining processes that correspond to the energy-saving benefits and environmental concerns

The effect of pressure gradient and abrasive tool wear when polishing ceramic tiles

A series of experimental investigations were conducted to develop and describe the distribution of the pressure gradient below and across the topological surface of laboratory grinding tools on a ceramic tile during the gloss gaining process. The possibility of controlling the pressure required for the industrial polishing ceramic tiles would prevent excessive wear, directly reducing energy and water consumption. The present research aims to determine the effect of incremental surface pressure distribution in the polishing of ceramic tiles with line contact. For this purpose, two grinding devices were mounted together as a polishing head and built from the machine's base coordinate system on a CNC tribometer with a deflection angle of 2.2°. The grinding pressure was distributed gradually underneath and across the polishing tools by implementing a new polishing tool composed of a rotating shaft with pivot joint, helical springs, and two abrasive blocks attached to it. Due to the configuration of polishing tools with preferred process parameters, the impact of the material removal and gloss production was found to be minimized or maximized according to the chosen kinematics. Results implied that the process outcome in terms of gloss level and fine surface finish is influenced by the surface pressure (maximum at approximately more than 15 MPa) as well as the abrasive tool surface wear. Furthermore, in the manufacturing line, a higher wear rate is posed by the coarser abrasives but less wear rate on the finer abrasives with high gloss gaining

Halogen dryer for roselle tea production

Dried Roselle is produced from heating by using Halogen lamp which emits radiation that generates heat and vaporizes the moisture (water) content of Rosell

Parametric investigations of drying callophyllum inophyllum fruit for the oil extraction process

Lubricant is a chemical that reduce the friction. Lubricant is made of petroleum, this petroleum-based lubricant is dangerous, It will affect the ecology system. The demand of lubricant is kept increasing but the petroleum is decreasing over the years. The alternative way needs to find out. One of the alternative way is bio-lubricant. Bio-lubricant can be biodegradable by the bacteria and no pollution. Callophyllum inophyllum (CI) can be one of the ingredient to manufacture bio-lubricant because it has higher oil yield. To extract the oil of CI, drying process is necessary to carry out. In this project, a dryer is built to investigate the best parameter to dry CI and also find out which parameter is the most suitable to dry CI through the experiment. Drying curve is plotted to provide more understanding for the behaviour of drying of Calophyllum Inophyllum Fruits. Furthermore, the quantity of heat and the latent heat of vaporization were calculated to determined how much heat were needed to raise temperature and vaporize the moisture content inside callophyllum inophyllum