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Lubricants
Special Issues
Application of Solid Lubricants in Metal Processing
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Application of Solid Lubricants in Metal Processing

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 10323

Special Issue Editors

Prof. Dr. Álisson Rocha Machado

E-Mail Website
Guest Editor
Graduate Program in Mechanical Engineering, Pontifícia Universidade Católica do Paraná—PUCPR, Curitiba 80215-901, PR, Brazil
Interests: machining processes
Special Issues, Collections and Topics in MDPI journals
Dr. Leonardo Rosa Ribeiro da Silva

E-Mail Website
Guest Editor
School of Mechanical Engineering, Federal University of Uberlândia, Uberlândia 38408-144, MG, Brazil
Interests: surface engineering; lubrication; manufacturing; machining; tribology
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The processing of materials involving high pressures (e.g., machining, forming, and powder metallurgy) requires efficient lubrication during compaction to facilitate sliding, reduce forces and energy consumption, decrease the wear of tools or dies and improve the quality of the workpieces. The application of liquid lubricants in these processes usually provides good penetrability between the sliding surfaces, but they may not have load capacity, requiring a more efficient lubricant. Solid micro or nanoparticles such as molybdenum disulphide, calcium fluoride, aluminium oxide, titanium oxide, boron nitride, graphite, graphene and carbon nanotubes, among others, are applied directly to the tribological pair, added to the liquid lubricant or even added to the work material, contributing to the reduction of the coefficient of friction, heat generation and increased load capacity. The addition of these particles can also increase the thermal conductivity and improve the work fluids’ cooling capacity, ensuring lower temperatures and longer tool lives. Numerous investigations with solid lubricants have been published considering their effects on the process controlling variables, but articles showing the kinematics and the physical-chemical mechanisms of these lubricants are scarce.

In this Special Issue, the objective is to publish high-quality papers that can answer emblematic questions of the role played by solid lubricants in manufacturing processes. We are searching for articles that study relevant aspects of solid lubricants, including types, lubrication efficiency, methods of application, impacts on the process output variables (forces, power consumption, temperature, quality of the workpiece, and tool life) and sclerometry techniques used to determine the lubrication efficiency. Environmental and human health aspects related to the application of solid lubricants will be heavily privileged. Special emphasis will be given to studies of the mechanics of the tribological phenomena of friction, the physical-chemical mechanisms, and the in-situ kinematics of the solid lubricant particles. Experimental and theoretical models and simulations are welcome, as well as any related work that will contribute to the advancement in the science of solid lubrication in manufacturing processes.

Prof. Dr. Alisson Rocha Machado
Dr. Leonardo Rosa Ribeiro da Silva
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Solid lubricants
  • Manufacturing processes
  • Methods of application of solid lubricants
  • Friction and wear
  • Physical-chemical mechanisms
  • Nanofluids
  • Modelling and simulation
  • Machining
  • Forming
  • Powder metallurgy
  • Flood cooling
  • Minimum quantity of lubricant (MQL)

Published Papers (4 papers)

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Research

11 pages, 2413 KiB  
Article
Controlling the Solid-State Reaction in Fe-MoS2 Self-Lubricating Composites for Optimized Tribological Properties
by Gabriel Araujo De Lima, Aloisio Nelmo Klein and Kaline Pagnan Furlan
Lubricants 2022, 10(7), 142; https://0-doi-org.brum.beds.ac.uk/10.3390/lubricants10070142 - 06 Jul 2022
Cited by 2 | Viewed by 1349
Abstract
In this work, self-lubricating composites containing MoS2 and graphite dispersed in an iron matrix were produced by powder metallurgy and sintering. Previous studies demonstrate that MoS2 reacts with iron matrixes during sintering, making the production of Fe-MoS2 composites rather difficult. [...] Read more.
In this work, self-lubricating composites containing MoS2 and graphite dispersed in an iron matrix were produced by powder metallurgy and sintering. Previous studies demonstrate that MoS2 reacts with iron matrixes during sintering, making the production of Fe-MoS2 composites rather difficult. Therefore, this study focused on a potential solution to avoid or reduce this reaction, whilst still providing good tribological properties. Our results show that the addition of graphite retards the reaction of MoS2 with iron and that the combination of MoS2 + graphite results in composites with an optimized coefficient of friction associated with a low wear rate both in nitrogen and air atmospheres. Through adequate control of the lubricant’s particle size, composition, and processing parameters, self-lubricating iron-based composites with a low dry coefficient of friction (0.07) and low wear rate (5 × 10−6 mm3·N−1·m−1) were achieved. Full article
(This article belongs to the Special Issue Application of Solid Lubricants in Metal Processing)
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16 pages, 87678 KiB  
Article
Performance of MQL and Nano-MQL Lubrication in Machining ER7 Steel for Train Wheel Applications
by Kerem Yavuz Çamlı, Recep Demirsöz, Mehmet Boy, Mehmet Erdi Korkmaz, Nafiz Yaşar, Khaled Giasin and Danil Yurievich Pimenov
Lubricants 2022, 10(4), 48; https://0-doi-org.brum.beds.ac.uk/10.3390/lubricants10040048 - 23 Mar 2022
Cited by 31 | Viewed by 3165
Abstract
In the rail industry, there are four types of steel grades used for monoblock wheels, namely ER6, ER7, ER8 and ER9. ER7 steel is manufactured in accordance with the EN13262 standard and is utilized in European railway lines. These train wheels are formed [...] Read more.
In the rail industry, there are four types of steel grades used for monoblock wheels, namely ER6, ER7, ER8 and ER9. ER7 steel is manufactured in accordance with the EN13262 standard and is utilized in European railway lines. These train wheels are formed by pressing and rolling after which they are machined using turning process to achieve their final dimensions. However, machining ER7 steels can be challenging due to their high mechanical properties, which can facilitate rapid tool wear and thermal cracking. Therefore, while the use of coolants is critical to improving their machinability, using conventional flood coolants adds extra operational costs, energy and waste. An alternative is to use minimum quantity lubrication (MQL) cooling technology, which applies small amounts of coolant mixed with air to the cutting zone, leaving a near-dry machined surface. In the current study, preliminary tests were undertaken under dry conditions and using coated carbide inserts to determine the optimal cutting parameters for machining ER7 steel. The impact of the cutting speed and feed rate on surface roughness (Ra), energy consumption and cutting temperature were investigated and used as a benchmark to determine the optimal cutting parameters. Next, additional machining tests were conducted using MQL and nano-MQL cooling technologies to determine their impact on the aforementioned machining outputs. According to preliminary tests, and within the tested range of the cutting parameters, using a cutting speed of 300 m/min and a feed rate of 0.15 mm/rev resulted in minimal surface roughness. As a result, using these optimal cutting parameters with MQL and Nano-MQL (NMQL) cooling technologies, the surface roughness was further reduced by 24% and 34%, respectively, in comparison to dry conditions. Additionally, tool wear was reduced by 34.1% and 37.6%, respectively. The overall results from this study demonstrated the feasibility of using MQL coolants as a sustainable machining alternative for steel parts for rail wheel applications. In addition, the current study highlight the enhanced performance of MQL cooling technology with the addition of nano additives. Full article
(This article belongs to the Special Issue Application of Solid Lubricants in Metal Processing)
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22 pages, 6565 KiB  
Article
Improvements of the MQL Cooling-Lubrication Condition by the Addition of Multilayer Graphene Platelets in Peripheral Grinding of SAE 52100 Steel
by Bruno Souza Abrão, Mayara Fernanda Pereira, Leonardo Rosa Ribeiro da Silva, Álisson Rocha Machado, Rogério Valentim Gelamo, Fábio Martinho Cézar de Freitas, Mozammel Mia and Rosemar Batista da Silva
Lubricants 2021, 9(8), 79; https://0-doi-org.brum.beds.ac.uk/10.3390/lubricants9080079 - 16 Aug 2021
Cited by 13 | Viewed by 2366
Abstract
In most grinding processes, the use of cutting fluid is required, and research has been carried out to reduce the amount of fluid used due to costs and environmental impacts. However, such a reduction of fluid can result in thermal damage to the [...] Read more.
In most grinding processes, the use of cutting fluid is required, and research has been carried out to reduce the amount of fluid used due to costs and environmental impacts. However, such a reduction of fluid can result in thermal damage to the machined component because the amount of cutting fluid may not be sufficient to lubricate and cool the system. One way of improving the cutting fluid properties is to add micro or nanoparticles of solid lubricants. This paper aims to evaluate the performance of multilayer graphene platelets dispersed in cutting fluid and applied through the technique of minimum quantity of lubrication (MQL) during the peripheral surface grinding of SAE 52100 hardened steel. In this sense, the influence of these solid particles with respect to the surface and sub-surface integrity of the machined components was analyzed, performing the roughness and microhardness measurement and analyzing the ground surfaces. The results showed that the cooling–lubrication conditions employing graphene could obtain smaller roughness values and decreases of microhardness in relation to the reference value and components with better surface texture compared to the conventional MQL technique without solid particles. Full article
(This article belongs to the Special Issue Application of Solid Lubricants in Metal Processing)
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14 pages, 8280 KiB  
Article
Effect of Graphene Addition in Cutting Fluids Applied by MQL in End Milling of AISI 1045 Steel
by Vitor Baldin, Leonardo Rosa Ribeiro da Silva, Celso Ferraz Houck, Rogério Valentim Gelamo and Álisson Rocha Machado
Lubricants 2021, 9(7), 70; https://0-doi-org.brum.beds.ac.uk/10.3390/lubricants9070070 - 19 Jul 2021
Cited by 10 | Viewed by 2203
Abstract
The cutting fluids applied to the machining processes by the MQL process aim to reduce the machining temperatures and tool wear as well as improve the surface and dimensional finishing of the parts. To increase the efficiency of these fluids, graphene lubricating platelets [...] Read more.
The cutting fluids applied to the machining processes by the MQL process aim to reduce the machining temperatures and tool wear as well as improve the surface and dimensional finishing of the parts. To increase the efficiency of these fluids, graphene lubricating platelets are added. This work investigated the performance of three different cutting fluids with graphene sheets added and applied via MQL, considering the tool life, wear, and wear mechanisms acting on TiAlN-coated cemented carbide cutting tools in the end milling of AISI 1045 steel. We evaluated two vegetable- (MQL15 and LB1000) and one mineral-based (MQL14) neat oils and the same fluids with the addition of 0.05 and 0.1%wt graphene nanoplatelets. Dry cuts were also performed and investigated for comparison. The experiments were conducted under fixed cutting conditions (vc = 250 m/min, fz = 0.14 mm/tooth, ap = 1 mm, and ae = 20 mm). The end-of-tool-life criterion followed the guidelines of ISO 8688-1 (1989). To analyze the results, ANOVA and Tukey’s test were applied. The addition of graphene sheets in the vegetable-based cutting fluids effectively increased the lubricating properties, partially reducing the wear mechanisms acting on the tools. In addition, there was a predominance of thermal fatigue cracks and mechanical cracks as well as adhesive and abrasive wear mechanisms on the tools used in the cutting with the MQL15 and MQL14 fluids, indicating greater cyclical fluctuations in temperature and surface stresses. Full article
(This article belongs to the Special Issue Application of Solid Lubricants in Metal Processing)
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