Evaluation of Minimum Quantity Lubrication with Four Nozzles Using Nanofluid and Analysis of Nozzle Geometry and Position Effects on Drilling process by TOPSIS Method

Abstract

This study investigates the effect of various lubrication strategies, particularly minimum quantity lubrication (MQL), on temperature rise and surface roughness during the drilling process of CK45, aiming to enhance MQL parameters for improved machining performance. The study evaluates dry, flood, and MQL conditions using different lubricants, including Al₂O₃ nanofluid, CuO nanofluid, and palm oil. The MQL parameters such as nozzle geometry (circular, square, rectangular cross-sections), nozzle droplet size, nozzle angle, and nozzle distance were evaluated. Surface quality was also analyzed using scanning electron microscopy (SEM). The interaction of nozzle properties was assessed using ANOVA. Additionally, the optimal experimental conditions and alternatives were determined using the TOPSIS method. Experimental results revealed that Al₂O₃ nanofluid MQL reduced temperature and surface roughness by 42% and 48%, respectively, compared to flood lubrication, and by 56% and 54% compared to dry conditions. Rectangular nozzles outperformed circular and square ones, reducing temperature by 30%-38% and improving surface roughness by 31%-36%. The best conditions were identified as a 35-degree nozzle angle and 40 mm distance. SEM analysis confirmed that Al₂O₃ nanofluid minimized fine cracks and improved surface finish. This study highlights the importance of proper nozzle configuration, particularly in systems utilizing four nozzles, to increase lubrication efficiency.