Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrity
In manufacturing, cutting tools and component integrity are subjected to high-performance thresholds. The role of cutting fluids is pivotal in mitigating heat generation and friction at the tool-workpiece interface. This study explores the application of specifically designed, unconventional, and ec...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-03-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127525001108 |
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| author | Erik Abbá Alistair Speidel Zhirong Liao Donka Novovic Dragos Axinte |
| author_facet | Erik Abbá Alistair Speidel Zhirong Liao Donka Novovic Dragos Axinte |
| author_sort | Erik Abbá |
| collection | DOAJ |
| description | In manufacturing, cutting tools and component integrity are subjected to high-performance thresholds. The role of cutting fluids is pivotal in mitigating heat generation and friction at the tool-workpiece interface. This study explores the application of specifically designed, unconventional, and eco-friendly media, Deep-Eutectic Fluids (DEFs), which provide optimized fluid delivery to the cutting zone, regulating lubrication and cooling, while maintaining the surface integrity of the machined parts. To benchmark DEFs against traditional material removal methods, including dry, and wet (emulsion-based, Hocut 3380) processes, grinding was selected due to its thermal and lubrication demands. The results indicate that DEFs reduce the formation of severely deformed layers by 47% in comparison to conventional water-based coolants exhibiting superior lubricity, yielding more consistent deformation profiles and lower surface roughness. The generated residual stresses are closely comparable to those achieved using water-based metalworking fluids. This was substantiated by micromechanical testing, revealing a coherent failure mechanism at the machined edges for both DEF and wet-cutting media, significantly mitigating the adverse effects of dry machining. These findings highlight DEFs’ potential for industrial-scale adoption as a sustainable alternative in material removal processes, underscoring their capability to enhance process efficiency and environmental sustainability, or as an in-field portable cutting fluid. |
| format | Article |
| id | doaj-art-28a48194d4b040ec88807139fb249c40 |
| institution | Kabale University |
| issn | 0264-1275 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj-art-28a48194d4b040ec88807139fb249c402025-02-12T05:30:24ZengElsevierMaterials & Design0264-12752025-03-01251113690Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrityErik Abbá0Alistair Speidel1Zhirong Liao2Donka Novovic3Dragos Axinte4Rolls-Royce UTC in Manufacturing and On-Wing Technology, University of Nottingham, UKRolls-Royce UTC in Manufacturing and On-Wing Technology, University of Nottingham, UKRolls-Royce UTC in Manufacturing and On-Wing Technology, University of Nottingham, UK; Corresponding authors.Manufacturing Technology, Rolls-Royce Plc, UKRolls-Royce UTC in Manufacturing and On-Wing Technology, University of Nottingham, UK; Corresponding authors.In manufacturing, cutting tools and component integrity are subjected to high-performance thresholds. The role of cutting fluids is pivotal in mitigating heat generation and friction at the tool-workpiece interface. This study explores the application of specifically designed, unconventional, and eco-friendly media, Deep-Eutectic Fluids (DEFs), which provide optimized fluid delivery to the cutting zone, regulating lubrication and cooling, while maintaining the surface integrity of the machined parts. To benchmark DEFs against traditional material removal methods, including dry, and wet (emulsion-based, Hocut 3380) processes, grinding was selected due to its thermal and lubrication demands. The results indicate that DEFs reduce the formation of severely deformed layers by 47% in comparison to conventional water-based coolants exhibiting superior lubricity, yielding more consistent deformation profiles and lower surface roughness. The generated residual stresses are closely comparable to those achieved using water-based metalworking fluids. This was substantiated by micromechanical testing, revealing a coherent failure mechanism at the machined edges for both DEF and wet-cutting media, significantly mitigating the adverse effects of dry machining. These findings highlight DEFs’ potential for industrial-scale adoption as a sustainable alternative in material removal processes, underscoring their capability to enhance process efficiency and environmental sustainability, or as an in-field portable cutting fluid.http://www.sciencedirect.com/science/article/pii/S0264127525001108MachiningSurface IntegrityDeep-Eutectic FluidsMicromechanicsMetalworking Fluids |
| spellingShingle | Erik Abbá Alistair Speidel Zhirong Liao Donka Novovic Dragos Axinte Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrity Materials & Design Machining Surface Integrity Deep-Eutectic Fluids Micromechanics Metalworking Fluids |
| title | Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrity |
| title_full | Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrity |
| title_fullStr | Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrity |
| title_full_unstemmed | Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrity |
| title_short | Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrity |
| title_sort | addressing temperature challenges in machining deep eutectic metalworking fluids and their influence on surface integrity |
| topic | Machining Surface Integrity Deep-Eutectic Fluids Micromechanics Metalworking Fluids |
| url | http://www.sciencedirect.com/science/article/pii/S0264127525001108 |
| work_keys_str_mv | AT erikabba addressingtemperaturechallengesinmachiningdeepeutecticmetalworkingfluidsandtheirinfluenceonsurfaceintegrity AT alistairspeidel addressingtemperaturechallengesinmachiningdeepeutecticmetalworkingfluidsandtheirinfluenceonsurfaceintegrity AT zhirongliao addressingtemperaturechallengesinmachiningdeepeutecticmetalworkingfluidsandtheirinfluenceonsurfaceintegrity AT donkanovovic addressingtemperaturechallengesinmachiningdeepeutecticmetalworkingfluidsandtheirinfluenceonsurfaceintegrity AT dragosaxinte addressingtemperaturechallengesinmachiningdeepeutecticmetalworkingfluidsandtheirinfluenceonsurfaceintegrity |