Effects of ultrasonic nanolubrication on milling performance and surface integrity of SiCp/Al composites

• Published in: International journal of advanced manufacturing technology 2024-12, Vol.135 (9-10), p.4865-4878
• Main Authors: Hu, Shuguo, Wang, Xiaoming, Gao, Teng, Yang, Min, Cui, Xin, Liu, Dewei, Xu, Wenhao, Dambatta, Yusuf Suleiman, An, Qinglong, Wang, Dazhong, Li, Changhe
• Format: Article
• Language: English
• Subjects: Aerospace industry; Barrier layers; CAE) and Design; Computer-Aided Engineering (CAD; Cooling; Cutting energy; Dry machining; Engineering; Industrial and Production Engineering; Integrity; Lubricants; Lubricants & lubrication; Lubrication; Mechanical Engineering; Media Management; Milling (machining); Original Article; Particulate composites; Silicon carbide; Surface roughness; Workpieces
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-024-14785-0

High-volume fraction silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites are crucial materials in the aerospace industry, requiring precision milling to ensure accurate mating surfaces. However, achieving low-damage machining of SiCp/Al remains challenging. Traditional dry machining methods often affect surface integrity, while minimum quantity lubrication (MQL) has emerged as a more sustainable alternative to flood cooling. Despite this, the tool’s air barrier layer in MQL limits the lubricant flow to the tool-workpiece interface, reducing cooling and lubrication efficiency. To overcome this, an ultrasonic-enabled MQL (UV-MQL) technique for milling SiCp/Al is proposed. However, research on the effects and mechanisms of ultrasound-enabled nanolubricants in the milling of SiCp/Al composites remain limited. To fill this gap, milling experiments were conducted under various cooling and lubrication conditions. The performance of UV-MQL was assessed using key parameters such as milling force, specific cutting energy, and surface topography. Results showed that UV-MQL and UV-NMQL reduced specific cutting energy by 25.44% and 32.55%, respectively, compared to conventional MQL milling, while surface roughness ( Sa values) decreased by 14.44% and 38.22%. To further explain these outcomes, the anti-friction mechanism of the ultrasonically enabled nanolubricant was analyzed, focusing on droplet wetting, penetration, and film formation. These findings provide valuable insights for improving surface integrity in the SiCp/Al milling process.