Materials Today: Proceedings xxx (xxxx) xxx

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Performance comparison of dry, flood and vegetable oil based minimum

quantity lubrication environments during CNC milling of Aluminium
6061
Adhip Shukla a,⇑, Aman Kotwani a, Deepak Rajendra Unune a,b
a
Department of Mechanical-Mechatronics Engineering, The LNM Institute of Information Technology, Jaipur 302031, India
b
Department of Materials Science and Engineering, INSIGNEO Institute of in silico Medicine, University of Sheffield, United Kingdom

a r t i c l e i n f o a b s t r a c t

Article history: The minimum quantity lubrication in machining has been emerged as the sustainable manufacturing
Received 1 June 2019 techniques and being widely explored for industrial applications since last few years. The aim of this
Received in revised form 26 August 2019 paper is to explore the CNC milling performance while machining Aluminium 6061 under three different
Accepted 8 November 2019
environments viz. dry, flood and vegetable oil based minimum quantity lubrication (MQL) technique.
Available online xxxx
Taguchi L9 array was used to design the experiments, for three machining input parameters viz. cutting
speed, feed rate and depth of cut; considering the efficient use of limited resources. A fresh TiAlN coated
Keywords:
carbide PVD insert was used in end milling of Aluminium 6061T6 for each experimental run. A total of 27
Milling
Cutting fluid
experiments were performed for dry, flood and MQL environments. Average surface roughness was anal-
MQL ysed for each experiment and machining parameters for better surface finish were optimized. It was
Surface roughness observed that MQL provides the best surface finish out of all three cooling environments. Tool wear
Tool wear was also found to be reduced significantly in MQL environment as compared to dry and flood techniques.
It was concluded that MQL cooling technique can be used as a better alternative to dry or flood cooling
method.
Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific
committee of the International Conference on Mechanical and Energy Technologies.

1. Introduction
Metal cutting is the most widely used process in the manufac-
turing of different products all over the world; in fact, it is the core
of the manufacturing industries. It plays a major role in the manu-
facturing of various products from the automobile industry to high
precision components for the instrumentation and electronics
industries, and almost everywhere in-between [1]. The contribu-
tion of
15% in GDP of India demonstrates the significance of metal
cutting for the Indian economy. Among various industrial machin-
ing processes, the milling is a core machining operation. It is the
most common metal removal process encountered [2]. Towards
the end of the nineteenth century, heavy-duty milling machines
increasingly undertook and capture the market of machining oper-
ations previously performed by planing and shaping machines [3].
The problems faced while using planing and shaping machines
such as low cutting speeds due to start-and-stop motion
and impact loading on the tool when entering the work was
⇑ Corresponding author.
E-mail address: 16ume003@lnmiit.ac.in (A. Shukla).
encountered by the use of the end milling process. In the end
milling process, the tool generally rotates on an axis vertical to
the work-piece. It can be tilted to machine tapered surfaces. The
end milling operations generally use solid end mill or insert type
end mills. For solid end mills, the cutting teeth are located on both
the periphery of the cutter and the end face of the cutter body [4].
In case of insert type of end milling, the indexable insert based cut-
ting tools are commonly used.
Steel is one of the most commonly used material in the manu-
facturing industries but due to its mechanical properties like high
hardness, density and corrosion prone nature, it is now losing its
fight against Aluminium which is relatively soft, lighter and corro-
sion resistant. Moreover, the better machinability of Aluminium
reduces the overall machining costs. Aluminium 6061 T6 grade is
being widely used in the construction of automobile components,
yacht, bicycle frames, camera lenses, electrical fittings, couplings
and valves etc., owing to its medium-to-high strength, low cost
and the high strength-to-weight ratio [5]. Though T6 grade pos-
sesses good machinability, the high temperature generated during
machining imposes the decreases tool life, poor surface finish, and
reduces the dimensional sensitiveness of work material [6]. To

https://doi.org/10.1016/j.matpr.2019.11.060
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Mechanical
and Energy Technologies.

Please cite this article as: A. Shukla, A. Kotwani and D. R. Unune, Performance comparison of dry, flood and vegetable oil based minimum quantity lubri-
cation environments during CNC milling of Aluminium 6061, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.060
2 A. Shukla et al. / Materials Today: Proceedings xxx (xxxx) xxx
dissipate the heat generated during the machining, the cutting flu-
ids or metalworking fluids (MWFs) are used. Further, MWFs lubri-
cates and cool the work-piece and cutting tool it also helps to flush
of chips while machining. Since the beginning of the 20th century,
when F.W. Talyor first used water as MWF and concluded that it
increases the tool life significantly [7]; the MWFs became popular
in metal cutting operations. Although MWFs are beneficial in the
metal cutting, their uses in machining increase the overall machin-
ing costs by 15%, in addition to their management costs. Another
major problem with the use of MWFs is their damaging influence
on the environment [6]. Therefore, efforts are being put in the
direction of reducing the usage of MWFs in the metal cutting
towards sustainable manufacturing.
The minimum quantity lubrication (MQL) is one of the tech-
niques used to reduce the use of MWFs. The MQL sprays a very small
quantity of lubricant/coolant at the tool-chip interface at a certain
distance and angle through a nozzle with the help of compressed
air or gases [8]. Joshua et al. [4] have discussed the effect of cutting
parameters on the surface roughness during end milling of Alu-
minium 6061 under MQL. They found that the machining with
MQL, apart from being environmentally friendly, decreases the sur-
face roughness value much better as compared to the dry machining
condition. Singh et al. [9] also reported a similar kind of results while
machining of Inconel 718 alloy. They optimized the cutting condi-
tions with the flood, dry and MQL and concluded that the MQL has
a better performance keeping the tool wear less than ISO 3685 rejec-
tion threshold. Shao et al. [10] in their work on MQL as MWF for
grinding have found that MQL has significantly reduced the cutting
temperature and reduce the residual stresses. They claimed that the
MQL assisted grinding offers the reduced grinding forces, better sur-
face finish, and reduced residual stresses. Lugscheider et al. [11] in
his work discussed (MMS = minimum lubricant micro-spraying)
assisted reaming process of grey cast iron (GG25) and aluminium
alloy (AlSi12) with coated carbide tools and found positive results
over different cooling techniques. Machado and Wallbank [12] also
used MQL in the turning of medium carbon steel and reported that in
some cases, air or a mixture of air and water, or air and emulsion, has
shown better results than the overhead flooding application. Differ-
ent research in this area show that MQL is a versatile technique and
that it can be used in different machining operations also it provides
better results than dry machining and in some cases even better
than overhead flooding.
Although the MQL offers the reduced usages of MWFs, the use
of mineral oil based MWFs still imposes health related issues to
the operators and may cause environmental problems. The recent
growth of environmental thinking has changed the focus, from
biodegradability to renewability [13]. Recently, the researchers
have directed their attention to replacing those mineral oil bases
MWFs with environ-friendly vegetable oils MWFs [14]. The differ-
ent vegetable oils, viz. canola oil, soybean oil, rapeseed oil and sun-
flower oil etc., can be considered as cutting fluid in the machining
operations. The vegetable oils are generally properly emulsified
with the water to form the required cutting fluid and the water
can be mixed in different ratios for getting different cooling and
lubricating properties [15].
Burton et al. [15] found that the thinner chips thickness and less
burr amount was found when canola oil and water emulsion was
used when compared to conventional MWFs. Palm oil when used
for milling of AISI 420 was observed to yield longer tool life as dis-
cussed by Lawal et al. [16]. Lawal et al. in their review work
reported that vegetable oil-based machining is a great alternative
to mineral oils and it exhibits better machining performances but
investigation of machining under MQL of soft materials such as
Aluminium and medium carbon steel which forms built-up edges
on the tool and are sensitive to surface finish needs more work
to be done [17].
Please cite this article as: A. Shukla, A. Kotwani and D. R. Unune, Performance comparison of dry, flood and vegetable oil based minimum quantity lubri-
cation environments during CNC milling of Aluminium 6061, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.060
The objective of the work discussed is to investigate surface fin-
ish and tool wear in MQL environment with Canola oil as MWFs,
canola oil was selected by comparing it with different vegetable
oils on the basis of different properties required by MWFs. The
impact of cutting parameters such as cutting speed, feed and depth
of cut (DOC) at a constant flow rate and pressure of MQL, on tool
wear and surface roughness of aluminium 6061 during end milling
were discussed. It also compares up to what extent tool wear and
surface roughness will be affected when machining in flood, dry
and MQL with canola oil as a lubricant is used as MWFs.
2. Experimentation
2.1. Work-piece, tool and machining setup
The experiments were performed on aluminium 6061 plates to
investigate trends between surface roughness and different
machining parameters i.e. cutting speed, feed rate and depth of
cut. The different cutting environments were applied including
the dry, flood and MQL. For MQL environment, the canola oil was
used as the vegetable oil. The properties of Canola oil are shown
in Table 1. The experiments were conducted on an MTAB Max-
mill + vertical machining centre (VMC), whose spindle speed can
be varied from 150 RPM to 12,000 RPM with axis drive rated out-
put of capacity of 1.48 KW and spindle rated output of 3.7 KW-7.5
KW. Maximum limit of X, Y&Z axes are 480 mm, 360 mm and
500 mm, respectively, and the maximum feed rate that can be
achieved is 10000 mm/min. The control system provided in the
machine was Siemens 828D 3-axis continuous path system. The
material used for experiments was Aluminum 6061 T6 which con-
tains silicon less than 10% (dimension: 405 mm 
80 mm  16 mm). An ISO 9001:2008 certified indexable cutters
(SecotoolsÒ R217.69-1212.0-06-2AN) of diameter 12 mm with
TiAlN coated carbide PVD inserts (XOMX060204R-M05 F40 M)
was used a cutting tool. A fresh insert cutting edge was used for
each experimental run. The surface roughness of each cut was
measured using Mitutoyo SJ-210 profilometer which has a confor-
mance standard of the ISO 1997 with filter Gauss and a measuring
range of 17.5 mm along the X-axis and 360 mm (200 mm

+160 mm) along the Z-axis. The tool wear was analyzed using an
optical microscope. The MQL setup was externally attached as
shown in Fig. 1. It has a nozzle to change flow rate of cutting fluid
and air mixture.
2.2. Experimental procedure
The cutting speed, feed per tooth and depth of cut were selected
as input machining parameters while surface roughness was cho-
sen as response parameter. The three input parameters with three
levels of each were selected as shown in Table 2. Taguchi’s L9
orthogonal array was chosen to design the experiments for
Table 1
Canola oil properties.
Property Value
3
Relative density (g/cm ; 20C/water at 20C) 0.914–0.917
Refractive index (nD 40C) 1.465–1.467
Viscosity (Kinematic at 20C, mm2/sec) 78.2
Smoke point  (C) 220–230
Specific heat (J/g at 20C) 1.910–1.916
Flash point, open cup  (C) 275–290
Thermal conductivity (W/mK) 0.179–0.188
Cold test (15 H at 4C) Passed
Surface tension (mN/m) 25 ± 3
Cloud point (C) 3.3
Pour point (C) 31.66
 A. Shukla et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 1. VMC Setup.
Table 2
Input cutting parameters.
Parameters L1 L2
Cutting speed (mm/min) 100 200
Feed per tooth (mm) 0.045 0.0675
Dept of Cut (mm) 0.5 1 1.5
considered conditions. Taguchi’s design of experiments is a robust
experimental design technique which helps in reducing the total
number of experiments to be carried out using the orthogonal
array to find out the most optimum level of each performance
parameter [18,19]. Taguchi’s orthogonal arrays are widely used
to investigate the effect of input process parameters on the process
responses. The Signal to noise (S/N) ratio determines the level of a
desired signal to the level of background noise. The results were
analyzed with smaller-to-better S/N ratio characteristics since
lower the surface roughness value better will be the surface finish.
In total, twenty-seven experiments were carried out: 9 experi-
ments with dry environment, 9 with flood and 9 with canola oil
based MQL. The cutting fluid for MQL was prepared by emulsifying
Canola oil with water in 6% v/v ratio. The emulsion was prepared
from sonication of the two immiscible liquids (Water and Canola
oil) as shown in Fig. 2. Sonication is the act of applying ultrasound
energy to create mechanical vibrations which agitate particles in a
sample. It is mainly used for production of emulsions especially
nano-emulsion [20]. The emulsion prepared was brought to room
temperature before it was used in MQL setup.
Fig. 2. Canola Oil and water emulsion (a) before (b) after sonication.
Please cite this article as: A. Shukla, A. Kotwani and D. R. Unune, Performance comparison of dry, flood and vegetable oil based minimum quantity lubri-
cation environments during CNC milling of Aluminium 6061, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.060
3
The mean cutting parameters were taken as suggested by tool
manufacturershown in Table 2, upper and lower limits were set
to get optimum results with consideration of VMC limits.
The machining parameters like spindle speed and feed rate
were calculated for each different experiment from the formulae
given below:
1000 V C
N¼ ð1Þ
pD
F ¼ N  Fz  Z ð2Þ
where N = Spindle Speed, Vc = Cutting Speed, D = Diameter of the
shank, F = Feed Rate, Fz = Feed/Tooth, Z = Number of tooth.
The surface roughness measurement was performed at 3
different locations. The cut-off wavelengths were kc = 0.8 mm
and ks = 2.5 mm and the speed of the diamond stylus was
0.5 mm/min. The profile parameter Ra was selected as the
response variable for the roughness. It measures the the arithmetic
average of the absolute values of the roughness profile ordinates.
3. Result and discussion
3.1. Result
L3
300 The objective of the present work was to investigate the effects
0.09 of input parameters on the surface roughness under three machin-
ing environments viz. dry, flood, MQL. The results of the experi-
ment in dry, flood and MQL condition are presented in Table 3.
3.2 Discussion
3.2.1. Effect of cutting speed on surface roughness
The effect of cutting speed at three different machining condi-
tions viz. dry, flood, and MQL, is presented in Fig. 3. It was observed
that an increase in the cutting speed attributes a decrease in the
surface roughness value implying better surface finish. It is well
known fact that the increase in cutting speed leads to a decrease
in the coefficient of friction between the work-piece and tool inter-
face. The chips formed under such conditions are continuous chips
which yield less contact between the work-piece and tool inter-
face, thus, resulting in a lower coefficient of friction which in turn
results in better surface finish. The experimental results show that
changing the cutting speed has a considerable effect on surface
roughness value. For all three environments, the optimum cutting
speed value is 300 mm/min (level 3). To achieve lower surface fin-
ish for any environment, higher cutting speed values are recom-
mended. Increasing the cutting speed by 200% in dry condition
leads to 26% drop in surface roughness value whereas in MQL there
is a drop of 13%. This shows that changing the cutting speed has a
little but considerable effect on surface roughness value. Among
three different environments, the MQL based environment was
found providing positive effects lowering the surface roughness
values. This improvement can be attributed to the optimum lubric-
ity and viscosity of the canola oil which results in smooth cutting
and further decrease in friction coefficient. The drastic temperature
rise at the tool work-piece interface causes a rapid tool wear in dry
condition which is directly connected to poor surface finish in dry
environment [21]. At 100 mm/min cutting speed there is an
improvement of 62.5% and 53.5% when MQL cooling technique is
adopted over dry and flood techniques respectively. At high cutting
speed of 300 mm/min the improvement resulted using MQL
reduces to 55.7% and 37% when compared to dry and flood tech-
niques respectively which proves the fact that MQL provides a
better results adopted at low cutting speeds.
4 A. Shukla et al. / Materials Today: Proceedings xxx (xxxx) xxx

Table 3 whereas in case of dry the surface roughness values changes from
Surface roughness values in different machining conditions. (1.16–3.317) which shows an increase in surface roughness value
S. Cutting Speed Feed/tooth Depth of Cut Surface Roughness by 186% this indicates the fact that the change in feed/tooth has
No. (mm/min) (mm) (mm) (lm) a great influence on the surface roughness value. Out of all the
Dry Flood MQL three scenarios discussed the MQL assisted cooling technique with
1 100 0.045 0.5 1.12 0.68 0.62
canola oil was found to have least surface roughness which can be
2 100 0.0675 1 2.1 1.54 0.79 attributed to the reduced friction between work-piece and tool due
3 100 0.090 1.5 3.95 3.55 1.28 to the enhanced lubrication at the cutting zone in MQL environ-
4 200 0.045 1 1.47 0.99 0.56 ment, during machining. At 0.045 mm feed/tooth 52% and 20%
5 200 0.0675 1.5 2.27 1.68 0.9
improvement in surface roughness values have been observed
6 200 0.090 0.5 3.41 2.65 1.12
7 300 0.045 1.5 0.89 0.41 0.48 when MQL is used over dry and flood respectively whereas at high
8 300 0.0675 0.5 1.79 1.31 0.83 feed/tooth of 0.09 mm there is improvement of 65.5% and 58% for
9 300 0.090 1 2.59 1.98 1.02 dry and flood environment, this indicates that at high feed/
tooth values the MQL technique provides more significant
improvements.

Dry Flood Canola 3.2.3. Effect of depth of cut on surface roughness

3 Fig. 5 shows the effect of depth of cut on the surface roughness
Surface Roughness (µm)

2.5 2.39 values at different machining conditions. The higher values of

2 1.9233
1.5
1
0.8967
0.5
0 perature at tool-chip interface. Therefore, a very large depth of cut
100
Cutting Speed (mm/min)
Fig. 3. Effect of cutting speed on surface roughness.
3.2.2. Effect of feed/tooth on surface roughness
The effect of feed/tooth under three machining environments
on surface roughness is displayed in Fig. 4. It was observed that
an increase of feed/tooth value results in a significant increase in
surface roughness value. Further, it was observed that the higher
values of feed/tooth results in poorer surface finish as attributed
by high surface roughness values. Higher values of feed/tooth lead
to segmental chips formation. These segmental chips when depos-
ited between work-piece and tool interface increases abrasion,
heat and interrupt cutting, thereby, leading to increased surface
roughness values. Higher feed rate also results in increased thrust
force and increased vibrations attributing in increased the surface
roughness. Therefore, selection of low feed/tooth values is recom-
mended for achieving a good surface finish. The feed/tooth value of
0.045 mm (level 1) is optimum value for all three environments for
this experimentation work. In MQL assisted canola oil surface
roughness values changes from (0.5533–1.14) having rise of 106%
in surface roughness value with a rise of 100% in feed/tooth value
2.383
depth of cut found to be having negative impact of surface finish.
1.7733 1.757
The trend was expected as the interaction area between the tool
and work-piece increases with increased DOC. This increased tool
1.2333 and work-piece interaction causes the formation of discontinuous
0.86 (segmented) chips as a result of increased resistance and hindrance
0.7767
from work-piece which results in the increase of friction and tem-
200 300 leads to a poor surface finish [21]. Increasing the depth of cut by
200% results in a rise of surface roughness value by 12.5% in dry
environment and only 3.5% rise in MQL environment this proves
the fact that DOC has a trivial effect on surface roughness values.
It was also found that MQL assisted lubrication provides better sur-
face finish than dry and flood techniques. With the use of MQL, the
tool-chip friction is reduced which results in reduced abrasion and
temperature of the cutting zone which further provides better
results. At DOC of 0.5 mm MQL provides animprovement of 59%
and 44% in surface roughness compared to dry and flood respec-
tively whereas at DOC 1.5 mm there is improvement of 62.5%
and 53% when MQL is adopted over dry and flood cooling this
clearly indicates that at high DOC MQL technique provides even
better results. A better surface finish i.e. lower surface roughness
value can be achieved at optimum level of depth of cut which is
1 mm (level 2) for all three conditions.
3.2.4. Effect of different cooling techniques on tool wear
The tool wear has been compared for different machining envi-
ronments viz. dry, flood and canola based MQL at lowest input
parameter setting (i.e. experiment no.1) in Fig. 6 and at highest
input parameter setting (i.e. experiment no. 9) in Fig. 7. The tool

Dry Flood Canola

Dry Flood Canola

Surface Roughness (µm)

2.4
Surface Roughness (µm)

3.7
3.317
2.37
3.2
1.9 2.107 2.053
2.7 2.7267 1.88
2.2 2.053 1.4 1.5467 1.5033
1.7
1.51
1.2 1.16 0.9
1.14
0.8567 0.8867
0.7 0.6933 0.84 0.79
0.2
0.5533 0.4
0.045 0.0675 0.09 0.5 1 1.5
Feed per tooth (mm) Depth of cut (mm)
Fig. 4. Effect of feed on surface roughness. Fig. 5. Effect of depth of cut on surface roughness.

Please cite this article as: A. Shukla, A. Kotwani and D. R. Unune, Performance comparison of dry, flood and vegetable oil based minimum quantity lubri-
cation environments during CNC milling of Aluminium 6061, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.060
 A. Shukla et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 6. Tool Wear at experimental condition 1: (CS = 100 m/min, F = 0.045, DOC = 0.5 mm).
Fig. 7. Tool wear at experimental condition 9: (CS = 300 m/min, F = 0.09, DOC = 1 mm).
wear at lowest input parameter setting was found to be less as
compared to that at highest input parameter setting. It was found
that in case of MQL assisted machining trivial tool wear present on
tool insert, whereas, significant tool wear observed in case of dry
and flood environmental conditions.
The canola based MQL attributed to lower friction and good
lubrication at work-tool interface. In dry condition, there exists
the highest friction and high cutting forces which in turn results
in more amount of tool wear. The flank wear for each cooling con-
ditions found increased at high levels of machining parameters
(see, Fig. 7) as compared to that of low levels of input parameters.
This is due to the fact that higher cutting speed and increased
depth of cut increases the temperature and abrasion at
workpiece-tool interface. Crater wear was also found in dry condi-
tion which can be attributed to high friction and force exerted from
continuous chip at tool face which further increases the tempera-
ture and softens the tool.
4. Conclusion
In this work, the experiments were performed to compare the
effect of cutting speed, feed/tooth and depth of cut on the surface
roughness values at three machining environments, namely, dry,
flood and MQL while machining Aluminium 6061T6. The following
conclusions are drawn based on the results of this work.
 There was significant improvement in surface finish of the
work-piece when MQL assisted cooling technique was used as
compared to dry and flood techniques.
 For all machining environments, the surface roughness found to
be decreasing with an increase in cutting speed value. The per-
centage improvement in surface roughness value offered by
MQL assisted machining is higher at low cutting speed value
as compared to high cutting speed value.
 Increasing the feed/tooth has a negative effect on surface rough-
ness in all three techniques. While using MQL, there is a signif-
icant improvement in surface roughness and with increase of
feed/tooth values, the MQL assisted cooling provides better fin-
ish as compared to dry and flood cooling.
Please cite this article as: A. Shukla, A. Kotwani and D. R. Unune, Performance comparison of dry, flood and vegetable oil based minimum quantity lubri-
cation environments during CNC milling of Aluminium 6061, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.060
5
 Poor surface finish was found with an increment in DOC in all
the three environments. The MQL provided better surface finish
as compared to dry and flood conditions. The percentage
improvement in surface roughness was found higher at highest
value of DOC in case of MQL assisted environment.
 MQL show most significant improvement in surface roughness
at low cutting speeds and high feed/tooth and high DOC.
 Out of all three machining parameters surface roughness was
mostly affected by feed/tooth. It is advised to keep low feed/-
tooth values to improve surface finish and decrease tool wear.
 It was observed that tool wear was minimum when machining
was done in MQL environment. Flank wear and crater wear was
found to be increased at higher values of input parameters. It is
suggested to optimize the machining parameters; as higher
input values can lead to catastrophic failure of the tool edge.
 The optimum values of better surface finish recommend from
this work are cutting speed of 300 mm/min, feed/tooth of
0.045 mm and depth of cut of 1.00 mm for all three machining
environments.
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Please cite this article as: A. Shukla, A. Kotwani and D. R. Unune, Performance comparison of dry, flood and vegetable oil based minimum quantity lubri-
cation environments during CNC milling of Aluminium 6061, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.060