Improvement in the hard milling of AISI D2 steel under the MQCL condition using emulsion-dispersed MoS2 nanosheets

Abstract

The present work shows the process for MoS2 nanosheet production by liquid N2-queched bulk, a novel method having highly efficient, green, and facile operation. The produced MoS2 nanoparticles are suspended in minimum quantity cooling lubrication (MQCL)-based fluid to form nanofluid used for the hard milling of AISI D2 steel. The study aims to improve the hard-milling performance assisted by the MQCL technique using MoS2 nanofluid. ANOVA analysis is used to evaluate the effects of three input machining variables, including nanoparticle concentration, cutting speed, and material hardness on cutting forces. The results indicate that the better cooling effect from the principle of the Ranque-Hilsch vortex tube of the MQCL device combined with the better lubricating performance from MoS2 nanofluid brings out the sustainable alternative solution for machining difficult-to-cut material. Moreover, the experimental results provide the technical guides for the selection of proper values of nanoparticle concentration and cutting speed while ensuring the technological, economic, and environmental characteristics.