Evaluation of MQL broaching AISI 1045 steel with sesame oil containing nano-particles under best concentration

Cutting fluid could improve the machining efficiency and reduce the energy consumption during broaching process. However, the commercial cutting fluids (CCF) contain harmful constituents causing various environmental threats. Vegetable oil based nanofluids, which contain nanoparticles in the environmentally friendly vegetable oils, could be regarded as a potential alternative for cutting fluids. In this paper, the best concentrations of three sesame oil-based nanofluids containing Fe3O4, Al2O3, Carbon nanoparticles respectively were obtained. Then, the experiments on broaching AISI 1045 steel under MQL lubrication were conducted. The results showed that nanofluid (total weight:30 g) containing 160 mg Carbon produced the best lubricating effect. Its reduction of the average broaching load peak and load valley were 725 N and 614 N, which were 115.7%, 118.5% higher than those of CCF. And its root mean square error (RMSE) of broaching vibration signal was 36.15% lower than CCF. Also, the best surface quality was obtained. Cost analysis for the application of nanofluids is done in the present work. The sesame oil-based Carbon nanofluid (160 mg) has both environmental and efficient benefits for industrial application. [Display omitted] •Sesame oil-based carbon nanofluids effectively improved broaching performance.•Carbon nanoparticles have good load reduction and vibration suppression capability.•Nanofluids with MQL significantly reduce broaching costs.