INVESTIGATIONS ON THE EFFECT OF IONIC LIQUID (BMIMBF4) BASED METAL

WORKING FLUIDS APPLIED USING MINIMUM QUANTITY LUBRICATION SYSTEM ON

SURFACE ROUGHNESS

PANNEER R

1*, PANNEERSELVAM T

2, VARANASI VISWANATH KARTHIKEY

3

ABSTRACT

Metal Working Fluids (MWF) are the foremost source of health risks for machinists apart from being the cause of

environmental degradation which calls for research in the field of lubrication systems such as Minimum Quantity Lubrication

(MQL) machining with Green Cutting Fluids. Ionic Liquids (IL) are a new family of eco-friendly chemicals that have great

potential to be used as Metal Cutting Fluid in MQL machining. This work deals with the investigation on the effect of adding a

small quantity of an IL, 1-Butyl-3-Methylimidazolium Tetrafluoroborate (BMIMBF4) to a Metal Working Fluid (MWF)

formulation applied using MQL System on Surface Roughness (Ra) during machining of Carbon Steel AISI 1040. The effect

of such MWF formulations with IL on the roughness of the surfaces generated in turning process is investigated when the

MWFs are applied using Drop by Drop gravity based Mechanical Lubrication (DDL) System under orthogonal cutting

conditions. Roughness (Ra) values are measured, analyzed using statistical methods and the cutting conditions are optimized

for minimum Ra. It is observed that adding minute quantities of Ionic Liquid with MWFs resulted in improved Surface Finish as compared to any other cutting environments. As this formulation contains Neem Oil, Water and a Green Chemical, it is

sustainable, renewable, biodegradable and eco-friendly. The usage and disposal of this MWF will not affect the marine/aquatic

system and ground water source. Moreover the fumes generated or the physical contact with the MWF will not subject the

machinists to any major health ailment.

Key words: 1-Butyl-3-Methylimidazolium Tetrafluoroborate (BMIMBF4); Drop by Drop Lubrication (DDL); Ionic Liquid

(IL); Metal Working Fluids (MWFs); Minimum Quantity Lubrication system (MQL) ; Titanium Nitride Coated Carbide Tool

(TiNCC); Uncoated Carbide Tool (UCC).

1. INTRODUCTION

As machining is a significant manufacturing process, need for attaining sustainability in machining is well recognized. The

major unsustainable issue in machining is the excessive use of conventional hydro carbon based Metal Working Fluids

(MWFs) which are typically applied in flood type application on the cutting part of the tool. These MWFs during machining

generate fumes and get spilled as micro level particles and suspend in the environment. The conventional MWFs are

environmentally dangerous as they affect the marine system and ground water on disposal after use. Human wellbeing related

problems associated with exposure to such MWFs are irritation of the eyes, nose, throat, skin, and lungs, and other severe

conditions such as; typhoid, asthma, dermatitis , acne, pneumonitis, and a variety of cancers (Kailas 2012). Pollutants produced

by the uncontrolled escalation of bacteria and the obnoxious odour also pose serious threat to living organisms. Therefore

conventional MWFs are major source of health hazards and environmental pollution which has to be replaced with

environment friendly MWFs. Vegetable oils with appropriate additives/Emulsions with vegetable emulsifiers can overcome

many of the problems of conventional MWFs. Ionic liquids (ILs) are the new innovative solution to this issue. ILs are a

possible family of environment friendly chemicals which can be used as additives to the Vegetable Oil based MWFs to

enhance the Heat Reduction, Friction Reduction, Lubricating Performance, Thermal Stability, Non-Flammability, Anti-Wear,

Extreme Pressure, Friction Modification, Corrosion Inhibition, Detergent Properties and Wettability. ILs have good flexibility

in molecular design and they are free from zinc, sulphur, and fluorine. They are mutually mixable with oils and emulsions

particularly with low viscosity oils and emulsions. ILs are principally salts with melting point less than 100°C and those ILs

with melting point less than 25°C are identified as Room Temperature ILs. They contain an inorganic or organic anion and a

large organic cation that is unsymmetrical and includes Nitrogen or Phosphorus. The big size difference between anion and

International Journal of Pure and Applied MathematicsVolume 118 No. 18 2018, 2283-2293ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version)url: http://www.ijpam.euSpecial Issue ijpam.eu

2283

cation, and the resulting unsymmetrical distribution of charge, reduce the crystal lattice energy and thus ILs have low melting

point. The amalgamation between large unsymmetrical cation and smaller anion controls the properties of ILs. The problems

associated with conventional MWFs and advantages of ILs motivated this research which uses a green cutting fluid with an IL

as additive with Gravity based Drop by Drop Lubrication (DDL) Method which uses only minimum quantity of the MWFs.

This research work, studies the effects of ILs as additives to a green oil and its emulsions applied in DDL mode, during turning

of carbon steel AISI 1040. In the Indian scenario, since most of the edible oils are economically not feasible for industrial

applications, there is a necessity to seek for other viable substitute (Joseph et al. 2007). A non-edible vegetable oil of Indian

origin, the Neem oil is selected which is generally not used for cooking but produced in large quantities (Jain & Suhane 2012)

in India, is selected as the base oil. The Ionic Liquid that is selected for this research work is 1-Butyl-3-Methylimidazolium

Tetrafluoroborate (BMIM.BF4) because it is established as a good lubricant in many earlier research works involving

lubrication of surfaces.

2. LITERATURE REVIEW

The need for accomplishing sustainability in machining is well established because it is the most significant secondary

manufacturing process (Lu et al. 2011). The foremost unsustainable issue in machining is the profligate and reckless use of

conventional MWFs which are mostly applied in flood type application directed towards the rake and flank surface of the

cutting tool (Weinert et al. 2004). The conventional hydro carbon based and synthetic MWFs are extremely toxic to

environment, unsustainable, non-renewable, and non-biodegradable and have limitations on ecological performance (Kailas

2012, Skerlos et al. 2008, Suda et al. 2004). In addition, when dumped on ground or a water body, they affect the

marine/aquatic system and ground water source (Kailas 2012, Vaibhav Koushik et al. 2012). Hydro-carbon based MWFs are

also limited and a progressively decreasing resource (Kuram et al. 2013). Synthetics based MWFs naturally incorporate a great

deal of detergency and as a result can lead to skin problems (Edwards & Jones 1977). The semi-synthetic MWFs should not be

employed because the chlorine levels are higher than those allowed by the standards (Bork et al. 2014). Synthetic Chemicals

also have limitations on ecological performance (Skerlos et al. 2008, Suda et al. 2004). Therefore Conventional Hydro Carbon

and Synthetic based MWFs are the major cause for health ailments for Machinists such as Respiratory Ailments, Lung Cancer

etc. (Bennet, 1983) and ecological pollution such as Pollution of Water Bodies and Soil (Soković & Mijanović 2001). In

addition the cleaning of MWFSs from machine, work piece and the surroundings increases the cost of machining and

consumes energy (Paulo 2013). Several review papers have already provided indications on the scope of vegetable based

MWFs effectively replacing the Hydro Carbon and Synthetic based MWFs and further research efforts are continuing (Osama

et al. 2017). At constant cutting conditions, vegetable based MWFs with additives improved the machining performance by

reducing surface roughness (Ra), tool flank wear, cutting and thrust forces and cutting tool temperature (Kumar et al. 2015).

The vegetable based MWFs do not contain any chlorine element in its composition, maintain their low-level foam volumes,

and do not exhibit any acidity level. Nitrosamines, which cause problems to component quality and to machinist health are not

present in the vegetable cutting fluids. Therefore the efficiency of the use of vegetable based MWFs is proven (Bork et al.

2014). Vegetable oils are potential Oils which can act as base fluids for eco- friendly MWFs because of their superior inbuilt

qualities like excellent lubricity, bio-degradability, superior flash and fire points, lesser toxicity and adjustable viscosity in

emulsions, viscosity-temperature characteristics and low volatility (Srivastava & Sahai 2013). Lubricity of vegetable oils is

ascribed to their capability to get absorbed to the metallic surfaces and to form a firm mono-layer, with the polar head which

adheres to the metallic surfaces and the hydrocarbon chains get oriented in near normal directions to the surface (Somers et al.

International Journal of Pure and Applied Mathematics Special Issue

2284

2013a), Yakubu & Bello (2015) states that Neem oil is not only suitable for MWFs, but it is more effective than the soluble oil.

Srikant and Ramana (2015) have identified vegetable oil based emulsifier fluid which replaces both the mineral oil and

petroleum-based emulsifiers. It is established that it is possible to make vegetable oil–water emulsion systems with such

emulsifiers and different surface-active agents. These emulsions have excellent antirust properties (John et al. 2004). Vegetable

based MWFs have high Viscosity Index, and low evaporative losses. Overall, Vegetable oil-based MWFs exhibit several

excellent properties compared with mineral oils (Asadauskas 1996, Mobarak et al. 2014, Munoz et al. 2012, Usta el al. 2011,

Willing 2001). But the Vegetable based MWFs do have limitations with respect to stability and overall machining performance

(Lawal et al. 2012, Shashidhara & Jayaram 2010). Ionic liquids (ILs) are novel group of eco-friendly chemicals with the

possible application as lubricants (Libardi et al. 2013, Zhou et al. 2009). As lubricants, the synthetic ILs show outstanding

tribological performance and are better than any other lubricants, in terms of the friction reduction ability (Wang et al. 2004).

ILs are more thermally stable than hydrocarbon oils. They can uphold their stability up to 472°C whereas most oils decompose

at around 250°C (Mordukhovich et al. 2013). ILs as additives have many potential functions (Qu et al 2012). Most long alkyl

chains ILs are found to be mixable in vegetable oil. Since ILs consist of ions, they readily get adhered to the metal surfaces. X-

ray Photoelectron Spectroscopy (XPS) analysis suggests that the ILs develop shielding tribolayers which get transferred to the

contact area and get adhered to the metal surfaces to form a low-shear coating which results in reduction of friction and wear

(Somers et al. 2013a, Somers et al. 2013b). Hence ILs have become possible MWF additives. ILs are investigated only as

lubricants in predictable tribological environments involving sliding and rolling friction at comparatively lesser contact

pressures and temperatures. Schwab et al. (2009) have attempted to use ILs as Lubricants in Metal Forming. In the first

reported research in Metal Cutting, Pham et al. (2014) have investigated the effect of ILs as MWF additives in micro-

machining of Aluminum Alloy Al 5052, with low cutting forces and low temperature. Surface evaluation has demonstrated

significant friction and wear reductions from adding a small quantity (e.g., 5 wt %) of IL into a base oil. Yu et al. (2012)

suggest that oil-mixable ILs have wide applications as lubricant additives. The presence of even a very little quantity of IL (1%

concentration by weight), as an additive with vegetable oil in MQL mode, significantly affects the tribology of the machining

process, as compared to dry cutting, conventional flood-cooled cutting, and machining with neat vegetable oil applied in MQL

mode (Dhar et al. 2006, Goindi et al. 2015). A research work where Guanidinium ILs have been employed as lubricants

established that ILs possess better anti-friction and anti-wear performance in wide temperature range (Huang et al. 2017).

Application of vegetable oils and ILs have resulted in positive outcomes in terms of reducing cutting temperature, cutting

forces, surface roughness and many other (Osama et al. 2017).

Use of Minimum Quantity Lubrication (MQL) with vegetable oil based MWF in machining is acceptable from the standpoint

of environment pollution because the machining is done with very little amount of oil many times less than the conventional

MWFs. This type of MQL application reduced cutting force by 17% which actually means a reduced amount of power

consumption which is significant in terms of sustainability (Ekinovic et al. 2015). In MQL, it is observed that there is a

reduction of about 10–30 % Cutting Temperature and 5-28% reduction in Cutting Forces (Rahim et al. 2015). The key to the

success of MQL is the MWF with advanced tribological properties (Shen 2008). MQL flow rate even at 15-20 ml/min

demonstrated better performance compared to dry machining (Boswell et al. 2017). In addition to selection of an appropriate

cutting environment with additives, method of application of MWFs, selection of Cutting Tools and Cutting Parameters also

influences the surface roughness. It is observed that Titanium Aluminium Nitride (AlTiN) coated tools demonstrated superior

performance in all aspects as compared to other coated tools and uncoated tools. Particularly built-up edge formation is

International Journal of Pure and Applied Mathematics Special Issue

2285

considerably reduced in the case TiN coated tools (Ahmed et al. 2017). Further, surface finish can be significantly improved

by choosing cutting parameters appropriately (Yang & Tarng 1998). Surface roughness reduces with increase in cutting speed

and reduction in feed rate (Benardos & Vosniakos 2003, Khandey 2009, Kumar et al. 2012, Dureja et al. 2014, Rao et al. 2013)

but the depth of cut does not play a significant role on roughness (Venkatesan et al. 2014). Surface roughness is also influenced

by tool geometry in addition to the cutting environment (Dogra et al. 2011, Özel et al. 2005). Literature also illustrates that,

apart from optimizing a single output, multi-objective optimization has also been addressed using Taguchi and other methods

(Yang & Natarajan 2010, Varghese et al. 2017). Hence, this research work investigates the effects of ILs as additives to MWFs

on the surface roughness during turning of carbon steel. The major impact of the work is the replacement of Conventional

hydro-carbon/ synthetic based MWF with a MWF formulation consisting of Green Oil, IL as additive to enhance cutting

performance and Vegetable Emulsifier. The potential of such green formulations are not yet explored adequately in the field of

metal cutting. The other major contribution of this work is the optimization of cutting conditions for the suggested MWF with

IL which is also not attempted in any earlier research work.

3. METHODOLOGY

To investigate the effects of ILs as additives to Neem oil on Surface Roughness, turning operations are carried out on an all

geared lathe. The work piece material chosen is carbon steel - AISI 1040 grade with carbon percentage of 0.44%. The work

piece dimensions are Ø 32 mm x 140 mm long and turning is carried over a length of 120 mm. Titanium Nitride Coated

(TiNCC) and Uncoated Tungsten Carbide (UCC) inserts of Triangular Geometry with carbide grade P30 are used as cutting

tools. A new cutting edge is used for each experiment. The experiments are conducted under different formulations of MWFs

and cutting environments as shown in Table 1. DDL method is used for application of MWFs for reduced consumption. The IL

is mixed with Neem Oil or its emulsions using mechanical stirring. The cutting parameters viz., Speed and Feed shown in

Table 1 are selected based on the machine settings. The Depth of Cut is kept constant considering the fact that it does not

influence the Surface Roughness significantly. Experimental plan is developed based on the widely used Design of Experiment

method developed by Taguchi (Aggarwal & Singh 2005, Hamdan et al. 2012). For four factors with multiple levels, a L16

Orthogonal Array is obtained. 16 experiments are conducted based on the Array as shown in Table 2. The measurement of

surface roughness is performed with Mitutyo‘s Measuring Instrument using a cutoff value of 0.8 mm (average of 3 readings per

sample, with 5 mm evaluation length for each reading). The values of surface roughness measured are given in Table 2. The

Analysis of Variance (ANOVA) for S/N ratio and Means are established for Surface roughness (Ra) and are tabulated in Table

3 and 4.

Table 1. Cutting Parameters and Conditions

Parameter Values Parameter Values

Speed (rpm) 1) 455 2) 685

Metal

Working

Fluid/

Cutting

Environment

1. Dry

Feed Rate (mm/rev) 1) 0.292 2) 0.583 2. Compressed Air

Depth of Cut (mm) 0.5 (Constant) - 3. Neem Oil

Cutting Tool

1) Uncoated

Carbide Tool -

UCC

2) Titanium

Nitride

Coated

Carbide

Tool - TiNCC

4. Emulsion (Neem Oil & Water in 1: 10 ratio)

5. Neem Oil with 1% BMIMBF4

6. Emulsion with 1% BMIMBF4

7. Neem Oil with 2% BMIMBF4

8. Emulsion with 2% BMIMBF4

4. RESULTS, DISCUSSIONS AND ANALYSIS

The L16 Array, Surface Roughness values obtained for each trail and the average roughness values are shown in Table 2.

International Journal of Pure and Applied Mathematics Special Issue

2286

Table 2. L16 Array and Surface Roughness

Job Cutting Environment Speed

(rpm)

Feed

(mm/rev) Tool

Roughness (Ra) Average

(Ra) 1 2 3

L1 MWF System - Dry 455 0.292 UCC 9.82 9.55 10.0 9.80

L2 MWF System - Dry 685 0.583 TiNCC 9.02 9.87 8.87 9.25

L3 MWF System - Compressed Air 455 0.292 UCC 8.82 9.58 8.22 8.87

L4 MWF System - Compressed Air 685 0.583 TiNCC 7.39 8.84 7.23 7.82

L5 MWF System - Neem Oil- Flood Cooling 455 0.292 TiNCC 5.27 3.84 3.82 4.31

L6 MWF System - Neem Oil- Flood Cooling 685 0.583 UCC 5.43 8.67 6.37 6.82

L7 MWF System - Emulsion- Flood Cooling 455 0.292 TiNCC 3.71 3.38 5.62 4.24

L8 MWF System - Emulsion- Flood Cooling 685 0.583 UCC 6.62 7.71 4.11 6.15

L9 MWF System - Neem Oil with 1% IL - MQL 455 0.583 UCC 4.75 6.75 5.96 5.82

L10 MWF System - Neem Oil with 1% IL - MQL 685 0.292 TiNCC 2.58 6.38 2.28 3.75

L11 MWF System - Emulsion with 1% IL - MQL 455 0.583 UCC 4.46 6.74 4.76 5.32

L12 MWF System - Emulsion with 1% IL - MQL 685 0.292 TiNCC 2.18 3.18 3.49 2.95

L13 MWF System - Neem Oil with 2% IL - MQL 455 0.583 TiNCC 3.80 4.86 4.46 4.37

L14 MWF System - Neem Oil with 2% IL - MQL 685 0.292 UCC 2.06 4.59 2.05 2.90

L15 MWF System - Emulsion with 2% IL - MQL 455 0.583 TiNCC 3.57 4.85 4.28 4.23

L16 MWF System - Emulsion with 2% IL - MQL 685 0.292 UCC 1.74 2.29 3.14 2.39

The Analysis of Variance (ANOVA) for Signal to Noise ratio and Means are established for Surface roughness (Ra) and are

tabulated in Table 3 and Table 4.

Table 3. Analysis of Variance for SN ratios

Source DF SeqSS AdjSS AdjMS F P

MWF 7 150.860 150.860 21.551 15.78 0.004

SPEED 1 6.309 6.309 6.309 4.62 0.084

FEED 1 28.972 28.972 28.972 21.22 0.006

TOOL 1 5.328 5.328 5.328 3.90 0.105

Residual Error 5 6.827 6.827 1.365

Total 15 198.296 Table 4. Analysis of Variance for Means

Source DF SeqSS AdjSS AdjMS F P

MWF 7 70.047 70.047 10.0068 29.26 0.001

SPEED 1 1.523 1.523 1.5232 4.45 0.089

FEED 1 7.000 7.000 7.0004 20.47 0.006

TOOL 1 3.195 3.195 3.1952 9.34 0.028

Residual Error 5 1.710 1.710 0.3420

Total 15 83.476

The sums of squares (SS) in the ANOVA Table for S/N Ratios and Means (Table 3 and 4) indicate the relative importance of

each factor. The Metal Working Fluids with biggest SS (150.86, 70.047) and Feed with the next higher SS (28.972, 7.000)

significantly influence the Surface Roughness. As per these tables, MWFs, Feed and Speed are also significant at a α-level of

0.10 because their p-values are less than 0.10 in both the Tables.

Table 5. Response Table for S/N ratio for Surface Roughness Table 6. Response Table for means for Surface Roughness

Level MWF Speed Feed Tool Level MWF Speed Feed Tool

1 -19.58 -14.99 -13.01 -14.93 1 9.527 5.871 4.901 6.009

International Journal of Pure and Applied Mathematics Special Issue

2287

2 -14.82 -13.73 -15.70 -13.78 2 5.567 5.254 6.224 5.115

3 -14.40 3 5.192

4 -13.91 4 4.783

5 -12.11 5 4.135

6 -11.39 6 3.637

7 -10.21 7 3.312

8 -18.44 8 8.347

Delta 9.37 1.26 2.69 1.15 Delta 6.215 0.617 1.323 0.894

Rank 1 3 2 4 Rank 1 4 2 3

The response tables, Table 5 and 6 show the average of surface roughness characteristics for each level of the factors. The

tables include ranks based on Delta statistics which compare the relative magnitude of effects. The Metal Working Fluids with

rank 1 and Feed with Rank 2 have the greatest influence on both the S/N ratio and the Mean.

Figure 1 Main effects plot for S/N Ratios for Surface Roughness

Figure 2 Main effects plot for Means for Surface Roughness Figure 3 Interval of plot of Surface Roughness Vs MWFs

In this work, the aim is to achieve minimum surface roughness. Hence the factor levels that minimize the Mean and maximize

the S/N Ratio are considered as the optimum factors. We can observe from the main effects plot for S/N Ratios and Means

(Figure 1 and 2), Neem Oil Emulsion with 2% Ionic Liquid as MWF, Titanium Nitride Coated Carbide Tool, 685 rpm speed

and 0.292 mm/rev Feed shall result in best performance in terms of Surface Roughness. To study the effect of eight different

Legend:

Ar Compressed Air

Dr Dry

Em Emulsion

Em+1 Emulsion+ 1% IL

Em+2 Emulsion+ 2% IL Oi Oil

Oi+1 Oil + 1% IL

Oi +2 Oil + 2% IL

TiNCC TiNCC Coated Tool

UCC Uncoated Tool

Oi+2Oi+1OiEm+2Em+1EmDrAr

12

10

8

6

4

2

0

MWF

RO

UG

HN

ES

S

Interval Plot of ROUGHNESS vs MWF95% CI for the Mean

The pooled standard deviation was used to calculate the intervals.

International Journal of Pure and Applied Mathematics Special Issue

2288

types of MWFs and Environments on surface roughness, a one way ANOVA between surface roughness and MWFs is plotted

(Figure 3) with confidence level of 95%. From the plot it is established that the out of these, the Emulsion with 2% IL results in

lowest Surface Roughness Mean and hence it can be considered as the best substitute for conventional cutting fluids. Further,

in order to validate the finding based on Taguchi‘s S/N Ratio Plot and One way ANOVA Plot, experiments are conducted with

Titanium Nitride Coated Tool as the Tool with 685 rpm as Speed 0.292 mm/rev as Feed with 6 different MWFs, the results of

which are presented in Table 7. The Dry Environment and Compressed Air are excluded in the validation experiments

considering the fact that they have not positively contributed to Surface Roughness reduction.

Table 7. Surface Roughness

No MWF Roughness (Ra)

1 Neem Oil 6.12

2 Emulsion 4.81

3 Neem Oil+1%IL 3.69

4 Neem Oil+2%IL 3.36

5 Emulsion+1%IL 2.87

6 Emulsion+2%IL 2.34

Figure 4 Interval of plot of Surface Roughness Vs MWFs

The bar chart based on the surface roughness values obtained in validation experiments done with TiNCC Tool with 685 rpm

speed, 0.292 mm/rev as Feed and the above six different MWFs are shown in Figure 4. As it can be seen from Table 7 and

Figure 4, the MWF ‗Emulsion made with Neem Oil with Water in the ratio of 1: 10 mixed with Ionic Liquid (BMIMBF4- 2%

concentration by weight) results in the lowest surface roughness value (Ra).

5. CONCLUSIONS

From the analysis of average roughness of the surfaces generated in the turning process, it is observed that adding a very small

quantity of IL (1 to 2% concentration by weight), with an emulsion of vegetable oil or neat Vegetable Oil and applied in DDL

mode, significantly enhanced the surface finish, as compared to other MWFs. Therefore, Vegetable Oils/Emulsions with IL

additives can be considered as an Eco-Friendly MWF substitute for Hydrocarbon and Synthetic based MWFs. The optimal set

of process parameters for minimizing the Surface Roughness during machining of AISI 1040 grade plain carbon steel work

piece are: Cutting Speed: 685 rpm, Feed: 0.292 mm/rev, Depth of Cut: 0.5 mm, Tool: TiNCC, MWF: Neem Oil Emulsion with

IL- BMIM.BF4 (2% Concentration by weight). At the Optimum Cutting Conditions, use of Neem Oil with 1% and 2% IL and

it‘s emulsion with 1% and 2% IL reduces the Surface Roughness by 40% to 62% as compared to use of Pure Neem Oil, as

shown in Table 8. Similarly at the Optimum Cutting Conditions, use of Neem Oil with 1% and 2% IL and it‘s emulsion with

1% and 2% IL reduces the surface roughness by 23% to 51% as compared to use of pure Emulsion, as shown in Table 9.

Table 8. Surface Roughness Reduction as compared to Pure Neem Oil as MWF

MWF Neem Oil Neem Oil +1%IL Neem Oil +2%IL Emulsion+1%IL Emulsion+2%IL

International Journal of Pure and Applied Mathematics Special Issue

2289

Roughness (Ra) 6.12 3.69 3.36 2.87 2.34

% Reduction - 40% 45% 53% 62%

Table 9. Surface Roughness Reduction as compared to Emulsion as MWF

MWF Emulsion Neem Oil +1%IL Neem Oil +2%IL Emulsion+1%IL Emulsion+2%IL

Roughness (Ra) 4.81 3.69 3.36 2.87 2.34

% Reduction - 23% 30% 40% 51%

REFERENCES

Aggarwal, A., & Singh, H. (2005). Optimization of machining techniques — A retrospective and literature review. Sadhana,

30(6), 699–711.

Ahmed, Y. S., Paiva, J. M., Covelli, D., & Veldhuis, S. C. (2017). Investigation of Coated Cutting Tool Performance during

Machining of Super Duplex Stainless Steels through 3D Wear Evaluations. Coatings, 7(127), 1-15.

Asadauskas, S., Perez, J.M., Duda, J.L. (1996). Oxidative stability and anti-wear properties of high oleic vegetable oils.

Lubrication Engineering, 52, 877–82.

Benardos, P.G., & Vosniakos, G. C. (2003). Predicting surface roughness in machining: A review. International Journal of

Machine Tools and Manufacture, 43(8), 833–844.

Bennett, E. O. (1983). Water based cutting fluids and human health. Tribology International, 16(3), 133–136.

Bork, C. A. S., Gonçalves, J. F. de S., Gomes, J. de O., & Gheller, J. (2014). Performance of the jatropha vegetable-base

soluble cutting oil as a renewable source in the aluminum alloy 7050-T7451 milling. CIRP Journal of Manufacturing

Science and Technology, 7(3), 210–221.

Boswell, B., Islam, M. N., Davies, I. J., Ginting, Y. R., & Ong, A. K. (2017). A review identifying the effectiveness of

minimum quantity lubrication (MQL) during conventional machining. International Journal of Advanced Manufacturing

Technology, 92, 321–340

Dhar, N. R., Kamruzzaman, M., & Ahmed, M. (2006). Effect of minimum quantity lubrication (MQL) on tool wear and

surface roughness in turning AISI-4340 steel. Journal of Materials Processing Technology, 172(2), 299–304.

Dogra, M., Sharma, V. S., & Dureja, J. (2011). Effect of tool geometry variation on finish turning - A review. Journal of

Engineering Science and Technology Review, 4(1), 1–13.

Dureja, J. S., Singh, R., & Bhatti, M. S. (2014). Optimizing flank wear and surface roughness during hard turning of AISI D3

steel by Taguchi and RSM methods. Production & Manufacturing Research, 2(1), 767–783.

Edwards, J., & Jones, E. (1977). Synthetic Cutting Fluids. Tribology International, 10(1), 29–31.

Ekinovic, S., Prcanovic, H., & Begovic, E. (2015). Investigation of Influence of MQL Machining Parameters on Cutting Forces

during MQL Turning of Carbon Steel St52-3. Procedia Engineering, 132, 608–614.

Goindi, G.S., Chavan, S.N., Mandal, D., Sarkar, P., & Jayal, A. D. (2015). Investigation of ionic liquids as novel metalworking

fluids during minimum quantity lubrication machining of a plain carbon steel. Procedia CIRP, 26, 341–345.

Hamdan, A., Sarhan, A. A. D., & Hamdi, M. (2012). An optimization method of the machining parameters in high-speed

machining of stainless steel using coated carbide tool for best surface finish. International Journal of Advanced Manufacturing Technology, 58(1–4), 81–91.

Huang, G., Yu, Q., Cai, M., Zhou, F., & Liu, W. (2017). Investigation of the lubricity and antiwear behavior of guanidinium

ionic liquids at high temperature. Tribology International, 114, 65–76.

Jain, A. K., & Suhane, A. (2012). Research Approach & Prospects of Non Edible Vegetable Oil as a Potential Resource for

Biolubricant - A Review. Advanced Engineering and Applied Sciences: An International Journal, 1(1), 23–32.

John, J., Bhattacharya, M., & Raynor, P. C. (2004). Emulsions containing vegetable oils for cutting fluid application. Colloids

and Surfaces A: Physicochemical and Engineering Aspects, 237(1–3), 141–150.

Joseph, P. V, Saxena, D., & Sharma, D. K. (2007). Study of some non-edible vegetable oils of Indian origin for lubricant

application. Journal of Synthetic Lubrication, 24, 181–197.

International Journal of Pure and Applied Mathematics Special Issue

2290

Kailas, V. S. (2012) Towards Sustainable and Eco-Friendly Cutting Oils. Presented at ‗Sustainability Seminars‘ on 30th April

2012 at Prairie Research Institute, Illinois Sustainable Technology Center, University of Illinois. USA.

Khandey, U. (2009). Optimization of surface roughness, material removal rate and cutting tool flank wear in turning using

extended taguchi approach. (Published Thesis). National Institute of Technology, Rourkela, India. Retrieved from http://

ethesis. nitrkl. ac.in/ 1378/

Kumar, B. S., Padmanabhan, G., & Krishna, P. V. (2015). Experimental Investigations of Vegetable Oil Based Cutting Fluids with Extreme Pressure Additive in Machining of AISI 1040 Steel. Manufacturing Science and Technology, 3(1), 1–9.

Kumar, N. S., Shetty, A., Shetty, A., Ananth, K., & Shetty, H. (2012). Effect of spindle speed and feed rate on surface

roughness of carbon steels in CNC turning. Procedia Engineering, 38(ICMOC 2012), 691–697.

Kuram, E., Ozcelik, B., & Demirbas, E. (2013). Environmentally Friendly Machining: Vegetable Based Cutting Fluids. Green

Manufacturing Processes and Systems. Materials Forming, Machining and Tribology, Berlin, Spriger-Verlog, 23-47.

Lawal, S. A., Choudhury, I. A., & Nukman, Y. (2012). Application of vegetable oil-based metalworking fluids in machining

ferrous metals - A review. International Journal of Machine Tools and Manufacture, 52(1), 1–12.

Libardi, A., Schmid, S. R., Sen, M., & Schneider W. (2013). Evaluation of ionic fluids as lubricants in manufacturing, Journal

of Manufacturing Process, 15(4), 414–418.

Lu, T., Gupta, A., Jayal, A. D., Badurdeen, F., Feng, S. C., Dillon, O. W., & Jawahir, I. S. (2011). A Framework of Product

and Process Metrics for Sustainable Manufacturing, Proceedings of the 8th Global Conference on Sustainable

Manufacturing, Abu Dhabi.

Mobarak, H. M., Mohamad, E. N., Masjuki, H. H., Kalam, M. A., Mahmud, K. A. H. Al, Habibullah, M., & Ashraful, A. M.

(2014). The prospects of biolubricants as alternatives in automotive applications. Renewable and Sustainable Energy

Reviews, 33, 34–43.

Mordukhovich, G., Qu, J., Howe, J. Y., Bair, S., Yu, B., Luo, H., Smolenski, D.J., Blau, P.J., Bunting, B.G., & Dai, S. (2013).

A low-viscosity ionic liquid demonstrating superior lubricating performance from mixed to boundary lubrication. Wear,

301(1–2), 740–746.

Munoz, R.A.A., Fernandes,D.M., Santos, D.Q., et al. (2012) Biodiesel: production, characterization, metallic corrosion and

analytical methods for contaminants. Chapter 6: Biodiesel – Feed stocks, Production and Applications,

http://dx.doi.org/10.5772/ 53655

Osama, M., Singh, A., Walvekar, R., Khalid, M., Gupta, T.C.S.M., & Yin, W.W. (2017). Recent developments and

performance review of metal working fluids. Tribology International, 114, 389–401.

Özel, T., Hsu, T. K., & Zeren, E. (2005). Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on

surface roughness and forces in finish turning of hardened AISI H13 steel. International Journal of Advanced

Manufacturing Technology, 25(3–4), 262–269.

Paulo J. D. (2013). Green manufacturing processes and systems. Springer E-Books. Berlin, Heidelberg.

Pham, M. Q., Yoon, H. S., Varsha Khare, & Ahn, S. H. (2014). Evaluation of ionic liquids as lubricants in micro milling -

Process capability and sustainability. Journal of Cleaner Production, 76, 167–173.

Qu, J., Luo, H., Dai, S., Blau, P., Bunting, B., Storey, J., & Lewis, S. (2012). Ionic Liquids as Multifunctional Ashless

Additives for Engine Lubrication. Research sponsored by the Vehicle Technologies Program, U.S. Department of

Energy. Retrieved from http://www.eere.energy.gov/vehiclesandfuels/pdfs/deer_2012/friday/presentations/deer12_qu.pdf

Rahim, E.A., Ibrahim, M. R., Rahim, A. A., Aziz, S., & Mohid, Z. (2015). Experimental investigation of Minimum Quantity

Lubrication (MQL) as a sustainable cooling technique. Procedia CIRP, 26, 351–354.

Rao, C. J., Rao, D. N., & Srihari, P. (2013). Influence of cutting parameters on cutting force and surface finish in turning operation. Procedia Engineering, 64, 1405–1415.

Schwab, P., Weyershausen, B., Hansel, R., & Finger, B. (2009) Use of ionic liquids for the non-cutting forming of metallic

work pieces. US Patent Application, Publication Number: US20090029887 A1.

Shashidhara, Y. M., & Jayaram, S. R. (2010). Vegetable oils as a potential cutting fluid-An evolution. Tribology International,

43(5–6), 1073–1081.

Shen, B. (2008). MQL Grinding using Nanofluids, (Published Ph.D Thesis). University of Michigan, East Lansing, MI. USA.

International Journal of Pure and Applied Mathematics Special Issue

2291

Skerlos, S. J., Hayes, K. F., Clarens, A. F., & Zhao, F. (2008). Current advances in sustainable Metalworking Fluids research.

International Journal of Sustainable Manufacturing, 1(1/2), 180-202.

Soković, M., & Mijanović, K. (2001). Ecological aspects of the cutting fluids and its influence on quantifiable parameters of

the cutting processes. Journal of Materials Processing Technology, 109(1–2), 181–189.

Somers, A. E., Khemchandani, B., Howlett, P. C., Sun, J., Macfarlane, D. R., & Forsyth, M. (2013). Ionic liquids as antiwear

additives in base oils: Influence of structure on miscibility and antiwear performance for steel on aluminum. ACS Applied Materials and Interfaces, 5(22), 11544–11553.

Somers, A.E., Howlett, P.C., MacFarlane, D.R., & Forsyth, M. (2013). A Review of Ionic Liquid Lubricants. Lubricants, 1(1),

3–21.

Srikant, R.R., Ramana, V.S.N.V. (2015). Performance evaluation of vegetable emulsifier based green cutting fluid in turning of

AISI 1040 steel. Journal of Cleaner Production, 108, 104-109.

Srivastava, A., & Sahai, P. (2013). Vegetable oils as lube base stocks :A review. African Journal of Biotechnology, 12(9), 880–

891.

Suda, S., Wakabayashi, T., Inasaki, I., & Yokota, H. (2004). Multifunctional application of a synthetic ester to machine tool

lubrication based on MQL machining lubricants. CIRP Annals - Manufacturing Technology, 53(1), 61–64.

Usta, N., Aydogan, B., Uguzdogan, E., & Ozkal, S. (2011) Properties and quality verification of biodiesel produced from

tobacco seed oil. Energy Conversion and Management, 52, 2031–9.

Vaibhav Koushik, A.V., Narendra Shetty, S., & Ramprasad, C. (2012). Vegetable Oil-Based Metal Working Fluid-A Review. International Journal on Theoretical and Applied Research in Mechanical Engineering, 1(1), 95–101.

T.K.Sethuramalingam, B.Nagaraj, ―A Comparative Approach On PID Controller Tuning Using Soft Computing Techniques‖,

International Journal of Innovations in Scientific and Engineering Research (IJISER), Vol.1, No.12, pp.460-465, 2014.

Varghese, L., Aravind, S.,& Shunmugesh, K. (2017). Multi-Objective Optimization of Machining Parameters during Dry

Turning of 11SMn30 Free Cutting Steel using Grey Relational Analysis. Materials Today:Proceedings, 4(2), 4196–4203.

Venkatesan, K., Ramanujam, R., Saxena, V., Chawdhury, N., & Choudhary, V. (2014). Influence of cutting parameters on dry

machining of Inconel 625 alloy with coated carbide insert - a statistical approach. ARPN Journal of Engineering and

Applied Sciences, 9(3), 250–258.

Wang, H., Lu, Q., Ye, C., Liu, W., & Cui, Z. (2004). Friction and wear behaviors of ionic liquid of alkylimidazolium

hexafluorophosphates as lubricants for steel/steel contact. Wear, 256(1–2), 44–48.

Weinert, K., Inasaki, I., Sutherland, J. W., & Wakabayashi, T. (2004). Dry machining and minimum quantity lubrication. CIRP Annals - Manufacturing Technology, 53(2), 511–537.

Willing, A. (2001). Lubricants based on renewable resource – an environmentally compatible alternative to mineral oil

products. Chemosphere, 43, 89–98.

Yakubo, S.O., & Bello, Y. (2015). Evaluation of Neem Seed Oil As a Cutting Fluid in Orthogonal Machining of Aluminum

Manganese alloy (Al-Mn) in Turning operation. European Journal of Engineering and Technology, 3(3), 15–24.

Yang, W. H., & Tarng, Y. S. (1998). Design optimization of cutting parameters for turning operations based on the Taguchi

method. Journal of Materials Processing Technology, 84(1–3), 122–129.

Yang, S. H., & Natarajan, U. (2010). Multi-objective optimization of cutting parameters in turning process using differential

evolution and non-dominated sorting genetic algorithm-II approaches. International Journal of Advanced Manufacturing

Technology, 49, 773–784.

Yu, B., Bansal, D.G., Qu, J., Sun, X., Luo, H., Dai, S., Blau, P.J., Bunting, B.G., Mordukhovich, G., & Smolenski, D.J. (2012).

Oil-miscible and non-corrosive phosphonium-based ionic liquids as candidate lubricant additives. Wear, 289, 58–64.

Zhou, F., Liang, Y., & Liu, W. (2009). Ionic liquid lubricants: designed chemistry for engineering applications. Chemical

Society Reviews, 38(9), 2590.

International Journal of Pure and Applied Mathematics Special Issue

2292

2293

2294