In the quest to enhance machining efficiency and tool longevity, a team of researchers from Konya Technical University’s Department of Mechanical Engineering has made a significant stride. Led by Onur Can Sirvan, the team has investigated the potential of nano-copper particles as additives in metal cutting fluids, with promising results that could reshape the energy sector’s approach to machining processes.
The study, published in ‘Materials Research Express’ (which translates to ‘Materials Research Express’ in English), delves into the tribological performance of copper nanoparticles coated with different ligands—gelatine, cellulose, and PVP—added to metal cutting fluids. The aim was to leverage copper’s high heat transfer coefficient and self-lubricating properties to reduce temperature in the chip area, minimize wear, and ultimately extend tool life while improving the surface quality of processed materials.
The research was conducted in four meticulous stages. Initially, the team performed UV absorbance, STEM, wettability, and PSA analyses on the synthesized nanoparticles. “The results were quite revealing,” Sirvan noted. “Gelatine emerged as the most effective ligand, setting the stage for further investigation.”
In the subsequent phase, pin-on-disc wear tests were conducted under varying speeds, loads, and ligand parameters. The friction coefficient, weight loss, and 3D topography images obtained from these experiments highlighted the superior performance of gelatine, followed by PVP and cellulose.
The third stage involved the chip removal process using the response surface method at different speeds, feeds, depths, and nano-fluid environments. Here, the team observed that the boron solution yielded the best surface roughness, while the gelatine-coated copper nanoparticle (CuNP-Gel) environment excelled in reducing cutting forces.
The final phase focused on tool wear experiments, comparing the boron solution and CuNP-Gel as coolant/lubricant liquids. The results were compelling: tool wear occurred more slowly in the CuNP-Gel environment, indicating a significant potential for extending tool life and reducing downtime in industrial applications.
The implications of this research for the energy sector are substantial. Enhanced tool life and improved surface quality can lead to more efficient machining processes, reduced costs, and increased productivity. As Sirvan explained, “The integration of nano-copper additives in cutting fluids could revolutionize machining operations, particularly in high-precision and high-demand industries like energy.”
This study not only sheds light on the potential of nano-copper additives but also paves the way for future research into advanced lubrication techniques. As the energy sector continues to evolve, innovations like these will be crucial in meeting the demands for efficiency, precision, and sustainability. The findings from Konya Technical University offer a glimpse into a future where machining processes are optimized, costs are minimized, and productivity is maximized—all thanks to the power of nanotechnology.