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46th SME North American Manufacturing Research Conference, NAMRC 46, Texas, USA
46th SME North American Manufacturing Research Conference, NAMRC 46, Texas, USA
Sustainability Assessment of Machining with Nano-Cutting Fluids
Sustainability Assessment of Machining with Nano-Cutting Fluids
Manufacturing Engineering Societya,*
International bConference 2017,aMESIC 2017, 28-30 June
H. Hegab , B. (Pontevedra),
Darras , H A. Kishawya
H. Hegab Vigo
2017,a,*
, B. Darrasb, H A.Spain
Kishawy
a
Machining Research Laboratory, UOIT, Oshawa, L1H7K4, Canada
Costing models Department
b for capacity
ofMachining
a
Research
Mechanical optimization
Laboratory,
Engineering, UOIT,
American in Industry
Oshawa,ofL1H7K4,
University Sharjah, Canada 4.0:
Sharjah, 26666, UAE Trade-off

between used capacity and operational efficiency

Department of Mechanical Engineering, American University of Sharjah, Sharjah, 26666, UAE
b

*Corresponding author. Tel.: +1-905-721-8668 (ext.5794);

E-mail address:
*Corresponding author. Tel.: +1-905-721-8668 (ext.5794);
Hussien.Hegab@uoit.ca
A. Santana , P. Afonsoa,*, A. Zaninb, R. Wernkeb
E-mail address: Hussien.Hegab@uoit.ca a

Abstract
a
University of Minho, 4800-058 Guimarães, Portugal
Abstract
b
Unochapecó, 89809-000 Chapecó, SC, Brazil
Proposing nano-cutting fluids contributes to facing the heat dissipation challenge during machining difficult-to-cut materials since
Proposing
they offer anano-cutting
highly observedfluidsthermal
contributes to facingvalue
conductivity the heat dissipation challenge
in comparison during
with the base machining
lubricants. difficult-to-cut
Thus, materials since
several nano-additives are
they offer to
employed a highly
improve observed thermal
the cooling conductivity
efficiency value in
of Minimum comparison
Quantity with the
Lubrication base lubricants.
(MQL) system since Thus, several
its heat nano-additives
capacity is much lowerare
Abstract
employed to improve
than the one achievedthe cooling
using floodefficiency of Minimum Quantity
coolant. MQL-nano-fluid Lubrication
technique (MQL)
offers two main system since its(a)
advantages; heat capacity the
enhancing is much lower
machining
than the performance
process one achievedasusing flood coolant.
the employed MQL-nano-fluid
nano-additives improvetechnique offers
the thermal andtwo main advantages;
frictional behavior, and(a) (b)
enhancing the machining
accomplishing a more
Under
process the
sustainable
concept oftheMQL
performance
process asasthe
"Industry
employed
systems
4.0", production
nano-additives processes
improve
applies an optimal
will and
the thermal
amount
be frictional
of oil compared
pushed
to the
toflood
be increasingly
behavior, interconnected,
and (b)strategy.
coolant accomplishing a morea
In this study,
information
sustainable
previous generalbased
process asonthe
assessment a MQL
real time
algorithm basis
systems has and,implemented
applies
been necessarily,
an tomuch
optimal amount findofmore
the efficient.
oiloptimal
compared and to In
thethis context,
flood
sustainable capacity
coolant parameters
process strategy. Inoptimization
this study,
levels duringa
goes beyond
previous
machining the
general
Inconel traditional
assessment aim of capacity maximization, contributing
algorithm has beenMulti-walled-carbon-nano-tubes
718 with MQL-nano-fluids. also
implemented to find the optimal (MWCNTs) for organization’s
and sustainable
and process
aluminum profitability
parameters and value.
oxide (Allevels during
2O3) gamma
Indeed,
machining lean
nanoparticles management
Inconel
have 718
been with and
utilized continuous
MQL-nano-fluids.
as nano-additives. improvement
The employedapproaches
Multi-walled-carbon-nano-tubes suggest capacity
(MWCNTs)
algorithm accommodates and optimization
aluminum
several oxide (Al
machining 2instead
O3) gamma
responses, of
and
maximization.
nanoparticlesmetrics
sustainable Thebeen
have study
and of capacity
utilized
indicators optimization
asregardless
nano-additives.
of theirThe and costing
employed
criteria. models
It hasalgorithm
been is an
thatimportant
accommodates
found research
several
the assessment topic results
machining
algorithm that deserves
responses,wereand
in
sustainablewith
contributions
agreement metrics
from and
bothindicators
the physical the regardless
practical
findings and
of the of their experimental
theoretical
conducted criteria. It has
perspectives. been
results. found
This paperthatpresents
the assessment algorithma mathematical
and discusses results were in
agreement
model for with the physical
capacity findingsbased
management of the on
conducted
differentexperimental
costing modelsresults. (ABC and TDABC). A generic model has been
© 2018 Theand
developed Authors.
it was Published
used to by Elsevier
analyze idle B.V.
capacity and to design strategies towards the maximization of organization’s
©© 2018
2018 The
The Authors.
Authors. Published
Published by
by Elsevier B.V.
Elsevier B.V.
Peer-review
value. The under responsibility
trade-off capacity of the scientific
maximization committee
vs of
operational NAMRI/SME.
Peer-review under responsibility of the scientific committee of the 46th SME North efficiency is highlighted and it is shown
American Manufacturing Researchthat capacity
Conference.
Peer-review under responsibility of the scientific committee of NAMRI/SME.
optimization might hide operational inefficiency.
Keywords: Sustainability; Machining; Assessment; Nano-Fluids; Minimum Quantity Lubrication.
© 2017 The Authors. Published by Elsevier B.V.
Keywords: Sustainability; Machining; Assessment; Nano-Fluids; Minimum Quantity Lubrication.
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
2017.
1. Introduction characteristics such as; high yield strength, high
1. Introduction characteristics
strength suchratio,
to weight as; high toughness,
yield strength,
very high
Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency
Difficult-to-cut materials such as titanium and nickel- strength
creep to
and weight ratio,
corrosion high toughness,
resistivity, and very wear
high high
Difficult-to-cut materials such as titanium
based alloys have effective industrial applications and nickel- creep and
resistance corrosion
[1]. In spite resistivity,
of the and
previous high wear
advantages,
based alloys
including have effective
automotive industrial
and aerospace applications
because of their resistance
several [1]. In have
problems spitebeen
of the previous
raised duringadvantages,
machining
1. Introduction
including automotive
promising mechanical, and aerospace
chemical, because of their
and physical several problemsmaterials
difficult-to-cut have been raised
(e.g. during
short tool machining
life, long
promising mechanical, chemical, and physical difficult-to-cut materials (e.g. short tool life, long
The cost of idle capacity is a fundamental information for companies and their management of extreme importance
in modern©production
2351-9789 systems.
2018 The Authors. In general,
Published it isB.V.
by Elsevier defined as unused capacity or production potential and can be measured
in several©under
2351-9789
Peer-review ways: tons of production,
2018responsibility
The Authors. Published
of available
by Elsevier
the scientific B.V.hours
committee of manufacturing, etc. The management of the idle capacity
of NAMRI/SME.
Peer-review underTel.:
* Paulo Afonso. responsibility
+351 253 of the761;
510 scientific committee
fax: +351 253 604of741
NAMRI/SME.
E-mail address: psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
2351-9789 © 2018 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 46th SME North American Manufacturing Research Conference.
10.1016/j.promfg.2018.07.033
246 H. Hegab et al. / Procedia Manufacturing 26 (2018) 245–254
H. A. Hegab, B. Darras, H A. Kishawy/ Procedia Manufacturing 00 (2018) 000–000
machining cycle time, and high heat generated at
cutting zone).
Nomenclature
Ndp number of selected design parameters
Nli number of levels per each design parameter
M number of selected machining outputs
N number of experimental cutting tests
NM number of studied sustainable metrics
Nk number of selected indicators for each
sustainable metric (k)
Ikp value for each sustainable indicator (p)
Mrj value for each machining response (j)
MQWj weighting importance factor for each
machining response (j)
SMWk weighting importance factor for each
sustainable metric (k)
IWkp weighting importance factor for each
sustainable indicator (p)
SFkpjn sustainable factor for each cutting test (n)
SIkpjn sustainable index for each cutting test (n)
WSIkpjn weighted sustainable index for each cutting
test (n)
TWSIn total weighted sustainable index for each
cutting test (n)
OStc an operational safety index used to express
the toxic chemicals exposure in the machining system
OShts an operational safety index used to express
the high-temperature surface exposure during cutting
OShss an operational safety index used to express
the high-speed surface exposure during cutting
In order to reduce the high cutting temperature,
coolant usage is required. Different experiments
showed that Minimum Quantity Lubrication (MQL)
using vegetable oil enhanced the wear behavior and
surface quality during machining difficult-to-cut
materials [2-4].
From an environmental perspective, the application
of machining with MQL is a sustainable and cleaner
cooling/lubrication approach as minimum amount of
oil is employed. Furthermore, it has a potential to
achieve a balance between the flood and dry
machining [5, 6]. However, MQL isn’t an efficient
replacement of flood coolant particularly when cutting
titanium and Inconel. One way to improve the cooling
and lubricant functions of MQL is using nano-fluids
which enhance the base fluid thermal and wettability
aspects [7-9].
Carbon nanotubes (CNTs) and aluminum oxide
(Al2O3) gamma nanoparticle are among the nano-
additives that have superior properties. The diameters
of these nano-additives vary from a few nanometers to
hundreds of nanometers and CNTs length ranges
between tens of nanometers to several centimeters
[10]. With a remarkable combination of mechanical
properties and an acceptable price along with the
superior properties including hardness, wear
resistance, excellent thermal conductivity, and high
strength and stiffness [11] makes the proposed nano-
fluid a good alternative. These properties provide the
resultant nano-fluid the ability to withstand the high
generated temperature during machining difficult-to-
cut materials. Also, they would enhance the nano-fluid
tribological functions since the employed nano-
additives work as spacers in the workpiece-tool
interface area to reduce the induced friction during
machining processes. Nano-cutting fluids have shown
promising effects on the cutting performance
characteristics through different cutting operations
such as turning, milling and grinding as has been
presented in some previous studies [12-15]. MQL-
nano-cutting fluid is one of the suggested techniques
to further improve the performance of MQL
particularly when machining difficult-to-cut materials.
The major important factor to improve the cooling and
lubricant functions in the MQL method is utilized
certain cutting fluids such nanofluid, which would
develop its wettability, convection and conduction
aspects [7, 8, 16, 17].
It has been stated that machining sustainability is
mainly focused on making the processes more
environmentally friendly and also reducing the energy
consumption during the process [18]. Also, the
product, process, and system levels should be linked
to achieve an effective sustainable machining
environment [19-21]. Five main sustainable
machining metrics have been presented and discussed
in a previous work [22], namely; energy consumption,
machining costs, waste management, environmental
impact and personal health and safety. Thus,
considering both machining quality characteristics as
well as the main machining sustainable metrics is an
important step to find the optimal and sustainable
process parameters settings.
A previous work [23] has presented a general and
promising assessment model for the sustainable
 H. Hegab et al. / Procedia Manufacturing 26 (2018) 245–254 247
H. A. Hegab, B. Darras, H. A. Kishawy / Procedia Manufacturing 00 (2018) 000–000

machining processes optimization as well as a solid Table 1. The cutting insert information for turning
sustainable machining guideline (including list of Inconel 718 [39]
indicators under each sustainable metric and defining
the measurement method for each given indicator). Inconel 718 cutting processes
The proposed algorithm output is an overall index CNMG 432MMH13A
Cutting insert
which expresses the whole sustainable machining (ANSI)
system in terms of the studied machining metrics, KENNAMETAL MCLNL-
indicators and machining responses. In general, the 164DNC5 with clearance
assessment model is considered as multi-objectives Tool holder angle 0o and rake angle -5o,
nose radius of 0.793 mm
solver for the sustainable machining processes
(Honed edge)
optimization.

In the current work, the assessment model has been
implement to provide the optimal and sustainable
processes parameters levels when machining Inconel
718 with both Multi-walled carbon nanotubes
(MWCNTs) and Al2O3 nano-fluids. The optimal
predicted levels accommodate both studied machining
responses (i.e. flank wear, surface roughness, and
power consumption) and the studied sustainable
metrics (i.e. energy consumption, CO2 emissions,
personal health, and operational safety) with their
corresponding indicators.
2. Experimentation and Methodology
In order to investigate the effects of MWCNTs and
Al2O3 nanoparticles on the MQL performance,
previous cutting results were used where different
levels of feed rate, cutting speed, and weight
percentages of added nano-additives have been
employed. In this work, Inconel 718 (ASTM SB 637)
has been utilized as the used workpiece for
experimentation. The depth of cut was set at 0.2 mm
and the cutting insert information is listed in Table 1.
Sensitivity analysis was incorporated in order to better
understand the cutting conditions effects throughout
the process. Through the use and installation of a
stand-alone booster system (Eco-Lubric) onto the
machine tool, an air-oil mixture offered a nominal
flow rate of 40 ml/hr and air pressure of 0.5 MPa. In
addition, ECOLUBRIC E200 was employed as a
vegetable oil used for experimentation. This is a cold-
pressed rapeseed oil type without additives.
Multi-walled carbon nanotubes (MWCNTs) with
13-20 nm average diameter, 95% purity, 10-30 µm
length, and 110 m2/g specific surface area have been
utilized for nano-cutting fluid preparations. Al 2O3
nano-particles properties were; 20 nm size, 95%
purity, and 138 m2/g specific surface area. The
dispersion of MWCNTs/Al2O3 into the base cutting
fluid was applied using an ultrasonic machine
(AQUASONIC-50HT) over duration of 3 hours at
60oC following by a stirring step using a magnetic
stirrer (Hot Plate Stirrer-3073-21) for 30 minutes in
order to ensure fully dispersion of MWCNTs and
Al2O3 nanoparticles into the base cutting fluid. Also,
in this study, the cutting speed, feed rate, and
percentage of added nano-additives were employed
with three levels each. Table 2 indicates the studied
independent process parameters and the assignment of
the corresponding levels for Inconel 718 cutting
processes. L9 orthogonal array (L9OA) based on the
Taguchi method was implemented for cutting tests.
The full factorial array in this work is L27OA (33);
however, fractional factorial array L9OA based on the
design of experiments methodology has been
employed to save time and cost.
Table 2. The levels assignment to design variables for
Inconel 718 cutting processes
Design Variables Symbols Level 1 Level 2 Level 3
Cutting feed A 0.2 0.3 0.4
(mm/rev)
Cutting speed B 30 40 50
(m/min)
Nano-additives C 0 2 4
(wt. %)
In this previous work, zeta potential for stability
analysis was performed to characterize the nano-
cutting fluid suspension stability. The Zetasizer-nano-
device is used to determine the zeta potential absolute
values for the resultant nano-fluids using different
weight percentages of employed nano-additives. The
248 H. Hegab et al. / Procedia Manufacturing 26 (2018) 245–254
H. A. Hegab, B. Darras, H A. Kishawy/ Procedia Manufacturing 00 (2018) 000–000

zeta potential results for the employed nano-cutting

fluids were in the range of moderate stability, Table 3. The plan of experimentation
according to the suspension stability evaluation Cutting speed Feed rate
Nano-
criteria [24]. Also, during the experimentation phase, Test no. additives
levels levels
(wt. %)
certain safety procedures (i.e. standard nano-additives
safety data sheets) have been applied to maintain a 1 1 1 1
standard health and safety level in the workshop to
avoid any harmful impacts for the machine operator. 2 1 2 2
Regarding the disposal method, the nano-fluids have
been carefully filtered before being released to the 3 1 3 3
sewer according to a standard material safety data
sheet [25]. 4 2 1 2

The conducted tests consist of nine experiments in 5 2 2 3

which the first column was assigned to the cutting
speed, the second column to the feed rate, and the third
column to the weight percentage of added nano-
additives as shown in Table 3. After each cutting test,
surface roughness (Ra), flank wear, and power
consumption data were collected. The flank wear was
measured using a toolmaker’s microscope after each
cutting pass. The average surface roughness (Ra) was
measured using a surface roughness tester (Mitutoyo
SJ.201). Ra is the arithmetic average height of surface
component (profile) irregularities from the mean line
within the measuring length used to describe the
vertical dimension of roughness. Ra is commonly
recognized, and the most used parameter to evaluate
the machined surface roughness. The used cut-off
length is 5 mm. After each cutting test, the surface
roughness tester is used in five random regions along
the machined surface, and the average value is
considered. Also, Power-sight manager device was
utilized to measure the power consumption during
machining. The cutting tests are replicated three times
and the average response value is calculated.
3. Experimental Results
The flank wear, surface roughness, and power
consumption results and observations when cutting
Inconel 718 using MWCNTs and Al2O3 nano-fluids
are presented in this section. The figures (1-3) are for
all the cutting tests shown in Tables 3 which based on
Taguchi method.
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2
3.1. Tool wear
The collected flank wear data during cutting with
MWCNTs and Al2O3 nano-fluids are provided in Fig.
1. A maximum flank wear (VB) of 0.4 mm was used
as the tool life criteria otherwise, in case of not
reaching the end of tool life criteria, the cutting
stopped after nine cutting passes. The results revealed
that both nanofluids have shown promising results in
comparison with the tests performed without any
nano-additives (i.e. tests 1, 6 and 8). The lowest flank
wear value was obtained after test 2 (i.e. cutting speed
of 30 m/min and feed rate of 0.3 mm/rev) when 2 wt.
% MWCNTs nano-fluid is used. When 4 wt. % Al2O3
nanofluid is used, test 4 showed the lowest tool wear.
Test 4 has been performed at cutting speed of 40
m/min and feed rate of 0.2 mm/rev. In addition, the
highest wear value was obtained at cutting test 8 which
has been performed without any nano-additives at
cutting speed of 30 m/min and feed rate of 0.4 mm/rev.
The nano-fluid significant improvements are mainly
attributed to the significant cooling and lubrication
properties of nano-fluids which improve the rake and
flank regions’ lubrication and wetting properties.
Therefore, better heat dissipation was accomplished as
similarly investigated in a previous work [26] and
consequently, the tool wear behavior could be
improved as has been discussed in some previous
studies [27-29].
 H. Hegab et al. / Procedia Manufacturing 26 (2018) 245–254
H. A. Hegab, B. Darras, H. A. Kishawy / Procedia Manufacturing 00 (2018) 000–000
Fig. 1. Flank wear results
3.2. Surface quality
The average surface roughness results when using
the two types of nano-additives are shown in Fig.2.
Both types of nano-fluid showed improvements in
machined surface quality; however, cutting tests 3 and
9 did not show significant improvement compared to
other cutting tests performed using nano-additives
which is attributed to the higher value of feed
(0.4mm/rev) used in these two tests.
Fig. 2. Surface quality results
The best surface quality is obtained after test 4 (i.e.
cutting speed of 40 m/min and feed rate of 0.2 mm/rev)
when using 2 wt.% MWCNTs nano-fluid. When 4
wt. % of added Al2O3 nano-particles is utilized, the
results showed that cutting test 7 (i.e. cutting speed of
50 m/min and feed rate of 0.2 mm/rev) offered the
better surface quality. Based on the presented results,
it can be concluded that both employed nano-fluids
offer significant improvements to the machined
surface quality. The improved in the measured tool
wear when using the nano-fluid are attributed to the
249
improvements in the wettability, convection, and
conduction of the fluid as results of adding the nano-
additives as confirmed in some previous works [8, 30,
31].
3.3. Power consumption
Fig. 3 shows the power consumption results when
using MWCNTs and Al2O3 nano-fluids. The lowest
power consumption was demonstrated at cutting test 2
(i.e. cutting speed of 30 m/min and feed rate of 0.3
mm/rev) when MWCNT is used and test 3 for the case
of Al2O3 nano-particles. In general, lower power
consumption is observed when MWCNTs is used
except cutting test 3 (i.e. cutting speed of 30 m/min
and feed rate of 0.4 mm/rev) which showed lower
power consumption of about 2% when Al2O3 nano-
fluid is used. The change in the power consumption
when using nano-additives is attributed to the
improvements in progression of tool wear due to
improvements in the cooling effectiveness, which led
to decrease the tool material thermal softening. By
other meaning, the nano-fluid mechanism affects the
tool wear progression and power consumption results
since the nano-fluid improve the cooling effectiveness
which decrease the cutting tool thermal softening, and
accordingly the tool wear and power consumption
values are decreased. Also, this is mainly due to the
resultant nano-mist mechanism since the employed
nano-additives work as spacers (see Fig. 4) to limit the
induced rubbing between the workpiece surface and
cutting tool as discussed in different previous studies
[32-35]. Also, the ploughed-off nano-additives left
thin exfoliated film (see Fig. 4) which forms a
protective nano-additive layer on the machined
surface. This mechanism is mainly called nano-
additives ploughing effect. This thin film decreases the
cutting heat transfer into the workpiece, and improves
the cutting process performance accordingly.
Fig. 3. Power consumption results
250 H. Hegab et al. / Procedia Manufacturing 26 (2018) 245–254
H. A. Hegab, B. Darras, H A. Kishawy/ Procedia Manufacturing 00 (2018) 000–000
Fig. 4. MQL-nano-fluid mechanism [9, 36]
4. Assessment of Machining Processes with MQL-
Nano-Cutting Fluids
A previous assessment algorithm [23] has been
applied in the studied nano-cutting fluid cases in order
to estimate the optimal and sustainable process
parameters levels by considering both the studied
machining responses (i.e. flank wear, surface
roughness, and power consumption) and the studied
sustainability metrics with their corresponding
indicators. The main steps of the used assessment
algorithm are summarized as follows;
 Selecting and defining the studied sustainable
metrics and their corresponding indictors
 Normalizing/scaling the studied machining
outputs, and sustainability metrics and indicators
 Weighting of normalized factors
 Calculating the overall sustainability assessment
index
The main equations [23] used to represent the
overall sustainability index in order to assess the
whole machining system in terms of the studied
machining metrics, indicators and machining
responses are given as shown in equations (1-4). The
overall sustainability index is between 0 and 1, where
higher indices mean better sustainable performance.
 I kp M r j if I kp and M r j are both LB or H B

 (1)
S Fkpjn =  M in(I kp ,M r j )
 otherw ise,
 M ax(I kp ,M r j )

 M in(S Fkpj )
 if S Fkpjis based on L B (2)
 S Fkpjn
S I kpjn = 
 S Fkpjn
if S Fkpjis based on H B
 M in(S F )
 kpj
W SI kpjn =SM W k M Q W j IW kp SI kpjn (3)
TW SIn = 
NM N k M
(4)
  W SI kpj
k=1 p=1 j=1
The first step is to select and define the used
sustainability metrics and their corresponding
indicators according to the general sustainable
machining guideline presented in a previous study
[23]. The studied metrics are the power consumption,
environmental impact (CO2 emissions), and personal
health and operational safety. The sustainability
indicator for the environmental impact is Ene which
represents the amount of resultant carbon dioxide
emissions per consumed kilowatt hour during cutting
processes using a standard set of emission intensity
values [37]. The selected sustainable indicators for the
personal health and operation safety metric are OStc,
OShts, and OShss (see the nomenclature section). OStc
values have been set as “1” with the tests done without
nano-additives and “2” with the tests done with nano-
additives. Regarding OShts values, they have been set
as 2 with tests performed with the classical MQL and
“1” with the tests performed using MQL-nano-fluids.
In terms of OShss, all values have been set as “1” either
with nano-additives or without nano-additives. The
studied machining outputs are; flank wear and average
surface roughness. The used assessment algorithm
could accommodate different weighting importance
factors for all studied factors (metrics, indicators, and
machining outputs); however, equally weighting
factors have been used in this study. The assessment
results for the studied cases (i.e. MWCNTs and Al2O3
nano-fluids) have been determined depending on the
previous considerations and using the used assessment
model equations. Also, the total weighted indices for
both cases have been calculated depending on the
previous mentioned considerations as shown in Fig. 5
and Fig. 6 for MWCNTs and Al2O3 nano-fluids,
respectively.
 H. Hegab et al. / Procedia Manufacturing 26 (2018) 245–254
H. A. Hegab, B. Darras, H. A. Kishawy / Procedia Manufacturing 00 (2018) 000–000
For both cases, it was found that cutting test 4 has
the highest weighted sustainablity index as shown in
both Fig. 5 and Fig. 6. Cutting test 4 has been
performed at cutting speed of 40 m/min, feed rate of
0.2 mm/rev and nano-additives weight percentage of 2
wt.%. At this predicted optimal condition, the average
surface roughness values were 1.35 µm and 1.76 µm,
while the flank wear values were 0.187 mm and 0.213
mm for MWCNTs, and Al2O3 nano-fluids,
respectively. This cutting test offers the same optimal
average surface roughness value when machining
Inconel 718 with MWCNTs nano-fluid (see Fig. 2 &
Table 4); however, the predicted average surface
roughness in case of Al2O3 nano-fluid isn’t the same
as the measured optimal value since the proposed
assessment algorithm is designed to achieve a multi-
objective optimization depends mainly on the
provided assumptions (e.g. studied indicators,
weighting factors). However, the predicted and
optimal average surface roughness values in case of
Al2O3 nano-fluid were in close agreement as shown in
Table 4.
Regarding the flank wear results, the model offers
the same optimal flank wear values when machining
Inconel 718 with Al2O3 nano-fluid (see Fig. 1 & Table
4). The predicted flank wear in case of MWCNTs
nano-fluid isn’t the same as the measured optimal
value; however, the predicted and optimal flank wear
values were in close agreement as shown in Table 4.
Fig. 5. Total weighted sustainability indices results of
machining Inconel 718 with MWCNTs nano-fluid
251
Fig. 6. Total weighted sustainability indices results of
machining Inconel 718 with Al2O3 nano-fluid
Table 4. The assessment model results versus optimal
experimental results
Machining MWCNTs Al2O3
outputs Model Exp. Model Exp.
Average surface 1.35 1.35 1.76 1.513
roughness (µm)
Flank wear 0.187 0.145 0.213 0.213
(mm)
On the other hand, cutting test 6 showed the lowest
assessment index in both employed cases (see Fig. 5
and Fig. 6). This cutting test has been performed at
cutting speed of 40 m/min, feed rare 0.4 mm/rev, and
without nano-additives. The flank wear and average
surface roughness results at cutting test 6 were; 0.32
mm and 6.23 µm, respectively. Regarding the average
surface roughness results, the model and measured
values are identical since both of them confirmed that
the worst surface quality occurred after cutting test 6
(see Fig. 2, Fig. 5 and Fig. 6). In terms of the flank
wear results, the model and measured values weren’t
in agreement since cutting test 8 showed the highest
flank wear (see Fig. 1); however, both of them
confirmed that the highest flank wear occurred during
machining Inconel 718 without nano-additives. Thus,
it can be concluded that the model outputs are
consistent with the physical findings in the current
experiments since the optimal experimental values and
model indices have been obtained under using the
MQL-nano-fluids.
Regarding the optimal levels of the nano-additives
concentration, it has been found that 4 wt. % for both
Al2O3 and MWCNTs nano-fluids showed the best
experimentally surface quality and tool wear;
however, no noticeable change has been observed
between 2 wt. % and 4 wt. % in the power
consumption results. The assessment model showed
252 H. Hegab et al. / Procedia Manufacturing 26 (2018) 245–254
H. A. Hegab, B. Darras, H A. Kishawy/ Procedia Manufacturing 00 (2018) 000–000
that cutting test 4 is the optimal test which has the
highest total weighted index. The nano-additives
concentration at this test is 2 wt. %. At this point, the
experimental investigations weren’t same as the
assessment model findings; however, the model
finding provides more physical sense as the highest
percentage of nano-additive (4 wt. %) could cause
more deteriorations to the cutting processes because of
the highest occurrence possibility of the drastic
ploughing effects which could increase the induced
nano-additives wear and accordingly increase the
overall tool wear. When there is an abundance of nano-
additives in the resultant nano-fluid, they collide with
and are impeded by the asperities on the work surface
and hence generate stronger cutting forces. As a
result, the nano-additive induced wear is increased
with increasing the nano-additives concretion as
similarly discussed in a previous work [38] (see Fig.
7). On the other hand, increasing the nano-additives
concentration would increase the resultant nano-fluid
thermal conductivity and would improve the heat
dissipation performance. Also, increasing the nano-
additives concentration means more nano-additives in
the workpiece-interface area, and therefore the
induced friction would decrease as can be seen in Fig.
7. Thus, the nano-additives concentration should be
carefully selected and optimized in order to strike a
balance between all previous considerations.
Fig. 7. The induced nano-additive wear versus nano-additives
concentration [38]
5. Conclusions
In this work, a previous sustainability assessment
model has been implemented to provide the optimal
and sustainable process parameters levels during
cutting Inconel 718 with MQL-nano-fluids. Two
nano-additive have been used for experimentation;
MWCNTs and Al2O3 nanoparticles. Two machining
outputs have been studied namely; flank wear and
average surface roughness, while three sustainability
metrics have been considered in the assessment
process; power consumption, environmental impact,
and personal health and safety. The assessment results
were in close agreement with the experimental
findings as both of them confirm the promising
improvements upon using MQL-nano-cutting fluids
compared to the classical MQL technique. Also, the
predicted values (i.e. flank wear and surface
roughness) were either identical or in close with the
optimal experimental values for both employed nano-
additives. In spite of that close agreement, the optimal
level of the nano-additives concentration was
confound parameter. The optimal experimental level
was 4 wt. %; however, the predicted level upon using
the assessment model was 2 wt. %. This investigation
confirmed some findings presented in a previous work
about the effects of the nano-additive concentration on
the nano-additives induced wear and coefficient of
friction. The increase of the nano-additives
concentration showed a noticeable increase in the
nano-additives induced wear which would negatively
affect the tool wear. On the other hand, the induced
friction could be decreased with increasing the nano-
additives concentration. Thus, it is recommend that the
nano-additives concentration should be carefully
selected and optimized in order to strike a balance
between all previous considerations. Finally, it is
recommend to study/include other sustainable
indicators such as the consumption of nano-additives
and the energy required for the dispersion in the
cutting fluid in order to provide a more comprehensive
understanding of the sustainability assessment of
machining with nano-cutting fluids.
Acknowledgements
The authors acknowledge the support of the Natural
Sciences and Engineering Research Council of
Canada (NSERC).
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