Abstract

The new technological solutions supporting hard machining processes are becoming an up-to-date research area. The enhancement of cooling lubrication efficiency in the cutting zone plays a crucial role in improving cutting performance. This paper investigates the effectiveness of Minimum Quantity Lubrication (MQL) using SiC nanoparticle-enhanced oil in the hard milling process of AISI D2 tool steel. The results are compared with dry and pure MQL modes based on criteria including cutting force components, surface roughness, tool wear, and tool life. The research results show that compared to dry and pure MQL, the SiC nanofluid MQL environment provides the best performance with reductions in feed force Fx (22.3–23.8%), thrust force Fy (20.5–55.3%), tangential force Fz (26.5–34%), surface roughness (37–62.3%), tool wear (46.1–73.3%), and increased tool life (80–200%). These findings demonstrate that the lubrication and cooling efficiency of the base oil is improved with the addition of SiC nanoparticles. The deep penetration of oil droplets into the cutting zone and the formation of the oil film significantly contributed to reducing friction and cutting heat. SiC nanoparticles not only improved the lubricating and cooling capabilities of the base cutting oil but also created secondary mechanisms within the cutting zone. Furthermore, monitoring cutting forces and surface roughness can be suggested as supplementary criteria for evaluating tool wear and tool life. This research will provide important technological guidance and a theoretical basis for the improvement of hard milling and application of the SiC nanofluid MQL technique.

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