The International Journal of Advanced Manufacturing Technology (2020) 109:345–376

https://doi.org/10.1007/s00170-020-05529-x

REVIEW ARTICLE

Progress for sustainability in the mist assisted cooling techniques:

a critical review
Gurraj Singh 1 & Munish Kumar Gupta 2 & Hussein Hegab 3 & Aqib Mashood Khan 4 & Qinghua Song 2,5 &
Zhanqiang Liu 2,5 & Mozammel Mia 6 & Muhammed Jamil 4 & Vishal S. Sharma 7 & Murat Sarikaya 8 & Catalin Iulian Pruncu 6

Received: 17 December 2019 / Accepted: 20 May 2020 / Published online: 1 July 2020
# Springer-Verlag London Ltd., part of Springer Nature 2020

Abstract
The proper implementation of sustainable manufacturing processes is an effective step towards a clean environment. The modern
cooling strategies applied in the manufacturing sector have presented promising solutions that enable economic growth and
ecological environment. In machining operations, cryogenic cooling and minimum quantity lubrication (MQL) have been
extensively utilized to replace conventional cooling techniques. Thus, this work offers a detailed review of major works focused
on manufacturing processes that use some of these sustainable cooling/lubrication modes (i.e., MQL, nanocutting fluids,
nanofluid-based MQL strategy, and other miscellaneous MQL upgrades). The main driver of this study is to create a bridge
between the past and present studies related to MQL and MQL upgrades. In this way, a new guideline can be established to offer
clear directions for a better economic vision and a cleaner manufacturing process. Thus, this review has mainly focused on the
machining of the most commonly used materials under MQL-related methods in conventional operations including turning,
milling, drilling, and grinding. Current work provides a detailed insight into the major benefits, limitations, as well as mecha-
nisms of cooling strategies that directly affects the machinability performance from a sustainable point of view. In summary,
further potential upgrades are indicated so that it will help to drive more sustainable approaches in terms of cooling and
lubrication environment during machining processes.

Keywords Sustainability . Minimum quantity lubrication . Nanofluids . Green machining . Cooling . Lubrication

1 Introduction overall cutting performance; however, they were criticized,

too, for being unhealthy and dangerous for the natural envi-
The employment of cooling agents, natural or synthesized, ronment. This is because the majority of such fluids contain
during machining processes was reported to improve the potentially harmful chemicals. In addition, the recycling cost

Gurraj Singh and Munish Kumar Gupta contributed equally to this work.

* Qinghua Song Mozammel Mia

ssinghua@sdu.edu.cn m.mia19@imperial.ac.uk

Gurraj Singh Muhammed Jamil

singh_gurraj@yahoo.co.in engr.jamil@nuaa.edu.cn

Munish Kumar Gupta Vishal S. Sharma

munishguptanit@gmail.com vishal.sharma@wits.ac.za
Hussein Hegab Murat Sarikaya
hussien.hegab@uoit.ca msarikaya@sinop.edu.tr
Aqib Mashood Khan
dr.aqib@nuaa.edu.cn Catalin Iulian Pruncu
c.pruncu@imperial.ac.uk
Zhanqiang Liu
melius@sdu.edu.cn Extended author information available on the last page of the article
346 Int J Adv Manuf Technol (2020) 109:345–376

of such fluids is very high, and their disposal poses several Sometimes, 2 to 10% concentrations of chlorine, sulfur, or
issues. Operators handling such chemicals over a long period other additives are added to both synthetic and semi-
are bound to suffer from skin or lung-related diseases. In the synthetic fluids, which permit to induce extreme pressure as
past two decades, researchers have focused on dry or near-to- well as boundary lubrication effects. Hence, these fluids are
dry machining processes that bypass the use of hazardous used in more difficult machining and grinding applications
chemicals. Due to its simple application and eco-friendly fea- [14]. Choosing a suitable coolant is paramount importance
tures, minimum quantity lubrication (MQL) has emerged as because it improves the machinability characteristics without
one of the best solutions to tackle this challenge. It has been affecting the operator’s health. The customary inhalations of
widely used in most of the machining operations ranging from such harmful mists often lead to serious health conditions [15,
turning to grinding [1, 2]. The results obtained after investi- 16]. Table 1 shows the comparison of different cutting fluids.
gating these processes clearly indicate the benefits of using the In terms of research motivation, this work offers the reader
MQL process while machining of various materials such as adequate information about the details of the significant
steel, aluminum, Inconel, titanium, composite etc. [3–7]. The benefits/limitations in many respects when such cooling ap-
primary benefit of this review is an in-depth analysis of the proaches are employed in machining operations. The current
main MQL strategies used in different machining operations. work does not only refer to the limitations and advantages of
It can be used later as a resource for significant improvements such cooling and lubrication techniques but also discuss the
in the existing machining process such as turning, grinding, tribological and heat transfer mechanisms behind applying
milling, drilling, etc. MQL or nanofluid-based MQL to evaluate the machining
In today’s competitive world, sustainability and harmony process performance. In addition, this review aimed to identi-
with the environment in the manufacturing industry are close- fy the future perspectives that can be implemented by using
ly related to economic production with very high quality. One MQL and nanofluid-based MQL techniques, and therefore,
of the primary factors that trigger the abundance of labor costs producing directions for an economical manufacturing pro-
in any manufacturing process is the repetitive replacement of cess and environmentally friendly approaches. This review
damaged tool inserts. The main cause of this issue is rapid tool has been organized based on the primary cutting operations
wear that takes place during machining processes. The work- and most machined materials that are performed by using the
tool friction engenders a very high wear rate corroborated with cooling and lubrication techniques mentioned above. The
high cutting temperature, which further aggravates the rate of complete framework of this review is presented in Fig. 2.
tool failure [8]. In order to reduce the cutting forces and the
cutting temperatures, the utilization of cutting fluids has be-
come a necessity in various machining operations [9]. These 2 MQL
cutting fluids aid lubricate the cutting area along with heat
removal. In addition, they allow improvement in surface qual- This practice represents to change the traditional cooling strat-
ity and chip breakability [10]. Selecting the appropriate cut- egy with a modern mist assisted lubri-cooling strategy. It has
ting fluid is an essential task because their performance may become prevalent from the past few years because researchers
vary from one process to another. Moreover, washing away apply it to obtain superior results regarding cutting forces,
the chips generated is another vital task performed by cutting surface roughness, temperatures, tool wear, tool life, etc.
fluids [11]. This process mainly focuses on the use of a minimal lubricant
The types of cutting fluids are divided into three major amount mixed with air outlet released from an air compressor.
categories: neat cutting-oils, cold gases, and water-soluble The employment of negligible quantities of lubricant leads to
fluids, as shown in Fig. 1. The straight oil is well known as an immense cost reduction. From the sustainability point of
neat oil or cutting oil. It is considered as the oldest class of view, it is indisputable that the process is extremely safe for
metal cutting fluid. These types of fluids are derived from both the environment and worker health. Mulyadi et al. [17]
petroleum or animal origin. The application of straight oil is made milling operations on AISI H 13 steel using MQL by
valuable only within very light duty machining operations considering an electrical energy input. The total consumption
[13]. Soluble or emulsifiable oils are such types of oil formed was determined and compared for all three environments (i.e.,
as droplets suspended in the emulsifier agent. Synthetic or dry, MQL, and flood) as is shown in Fig. 3. They presented
chemical fluids are generally mixed with different chemical the environmental aspects as well as energy benefits associat-
agents in water. The chemical agent includes amines, nitrites ed with the application of MQL system. The results obtained
phosphates, glycol, and germicides. The use of a chemical through MQL are precious as it allows improving the tool life
agent helps to improve the lubrication functions and decrease as well.
the surface tension. The synthetic fluids possess the best cool- Ginting et al. [18] organized a series of experiments to
ant potential; however, they lag in terms of lubrication abilities highlight the potential benefits associated with MQL com-
when they are compared to other capable coolants. pared to traditional techniques. Several calculations were done
Int J Adv Manuf Technol (2020) 109:345–376 347

Fig. 1 Cutting fluid classification

[12]

for cost and energy generation when using different cooling 1060 steel in turning process using the MQL system and other
techniques (i.e., MQL vs. traditional). Table 2 shows the com- available techniques. The Pugh matrix for the sustainability
parison of life cycle inventory in manufacturing using differ- assessment was developed to compare these techniques in
ent cooling techniques. It was noticed that some hazardous terms of different machining performance measures (i.e., tem-
environmental impacts such as human toxicity, eutrophica- perature, surface roughness, cutting force, etc.). In addition to
tion, and global warming could be reduced with MQL by these measured outputs, other responses (i.e., the ecological
87, 32, and 21%, respectively, compared to flood cooling. effect, coolant cost, operator health, and part cleaning cost,
The data from Table 3 proves the possibility of replacing the etc.) were investigated. The results are depicted in a Kiviat
flood cooling technique with MQL. In addition, Campatelli diagram, as shown in Fig. 4. When dry cutting and cold air
and Scippa [19] performed a comprehensive study to detect are applied, if the possible high temperature and friction in the
the environmental impact on the machining process. Dry, cutting zone do not have a negative effect on performance
flood cooling, and MQL techniques were compared by deter- outputs, these can be a practical application as cost and envi-
mining the energy rate released within each lubrication pro- ronmental effects are considered. It can be clearly said that the
cess. Further, the environmental impact was calculated in MQL is a more appropriate alternative to sustainability pro-
terms of CO2 equivalent for machining of 1 kg of material. duction since it can decrease production cost, negative effects
It was detected that MQL has a minimum environmental im- on environment and worker health, and finally productivity
pact. In another recent work, Mia et al. [20] machined the AISI will rise. However, it should be kept in mind that MQL

Table 1 Cutting fluid classification [15]

Type Pros Cons

Straight cutting oil Better lubrication Corrosion – Poor cooling Mist formation Fire hazard
protection
Soluble-cutting Good lubrication and Non-poisonous – Corrosion Bacterial Quick
fluids cooling problem growth evaporation
Semi-synthetic Good cooling Microbe control Corrosion Quick foaming Easily polluted –
fluids protection
Synthetic fluids Better cooling Corrosion Non-inflammable Poor lubrication Easily polluted –
protection
348 Int J Adv Manuf Technol (2020) 109:345–376

Fig. 2 The organization of the topics

method may cause errors induced by thermal damage on the performances on several materials. The prime motive of these
workpiece material, considering that highest temperature un- studies was to obtain the desired combination of working param-
der MQL was nearly four times more than traditional liquid eters in relationship to superior values of measured response.
especially in grinding operation [9]. The following subsections list the literature work connected with
the effectiveness of the MQL process in various machining pro-
cesses for example milling, turning, drilling, and grinding.

3 Effectiveness of MQL in machining

processes 3.1 Effectiveness of MQL in turning operations

There have been numerous studies conducted to evaluate the Turning is a machining process used for producing a desirable
effectiveness of MQL by corroborating different machining cylindrical shape by the assistance of a suitable cutting tool.
Int J Adv Manuf Technol (2020) 109:345–376 349

experiments using HSS and cemented carbide tools with

nanofluids. The particle size was taken in the size of 80 nm
and applied slowly to the cutting zone using the MQL tech-
nique. Variations in the fluid flow rates were made and the
results were compared with the simple dry turning as well as
with flooding technique. The inclusion of nanopowders into to
the base-liquid permits to improve several fluid properties
namely viscosity and thermal conductivity. The results
displayed a promising reduction in the roughness as well as
in the flank wear values. In another study, Ozbek and Saruhan
[23] worked the impression of the MQL on the surface char-
acteristics and wear modes driven by the turning of AISI-D2
steel. Positive results were obtained in both roughness and
tool wear values. Sarikaya and Gullu et al. [24] emphasized
the findings on the optimal value of MQL fluid flow rate along
with the optimized parameters of the cutting speed and fluid
type. The experimental design was made using the Taguchi’s
Fig. 3 Relative energy consumption in different cooling regimes [17] orthogonal arrays. The optimum levels of cutting parameters
were accomplished at an MQL flow rate of 180 ml/h, and
The single point cutting tool is generally used for this purpose. cutting speed of 30 m/min. In addition, Sreejith [25] studied
This process can be done under various cooling/lubrication the relative influences of the different lubrication strategies
conditions to raise the quality of the product and maintain while turning aluminum 6061 alloy using a diamond-coated
the cutting tool lifespan. Dhar et al. [21] have reported the carbide insert. Different comparisons were made between dry,
influence of MQL on the formation and morphology of the MQL, and flooded assisted turning. Cutting forces, flank wear
chips, generated temperature, and surface quality whan turn- as well as the surface roughness were investigated as mea-
ing AISI 1040 material. The experiments were performed sured machining outputs. The results support the fact that
using carbide inserts by varying cutting speed and feed rate. MQL leads to a significant improvement when compared with
Dry turning has been compared with soluble oil-based ma- dry turning. It offers similar results as compared to flood
chining as coolant. It was concluded that MQL highly im- cooling conditions. Furthermore, it has been found that the
proves the dimensional accuracy, and make a substantial de- environmental burden could be reduced substantially as well.
cline in the cutting temperature. They concluded that not only Khan et al. [26] turned AISI 9310 steel to evaluate the effec-
the MQL helps to improve the process parameters, but also tiveness of vegetable oil-based MQL, and a comparison was
works in resonance with the environment protection. Ondin carried out using dry and wet cooling to study the critical
et al. [8] compared the nanoparticles assisted MQL with dry machining performance measures. The responses such as chip
turning of PH 13–8 Mo stainless. The authors have concluded morphology, surface properties, wear, etc., were evaluated.
that nanoadditives assisted MQL has provided excellent sur- The MQL performance was much better compared to other
face finish and tool life. This case can be associated with great alternatives in terms of reducing the amount of heat produced.
lubrication and behaving like spacers has generated excellent A lower frictional force between the workpiece-tool interfaces
surface finish and less wear by preventing direct contact of accompanied this. In addition, the verification indicates that
tool main cutting edge. Prasad [22] performed turning the MQL leads to a much safer workplace with less heat and
fumes. Thus, besides improving the machinability character-
istics, MQL also improves the sustainability-related parame-
Table 2 Life cycle inventory comparison between TFC (traditional ters. Sarikaya et al. [27] used a particular cutting fluid to lower
flood cooling), MQL and CA (cold air) techniques [18]
the rate of tool wear that further permits to improve the surface
Input TFC MQL CA roughness. These series of experiments aimed to enhance the
machinability characteristics while turning Haynes 25 super-
Cutting energy (Wh) 323 295 223 alloy. The lubricant was introduced to the machining zone in a
Pumping energy (Wh) 5.12 × 10−2 0 0 small quantity via a specifically designed nozzle at a fixed
Compressor energy (Wh) 0 51 72 flow rate. The main emphasis during this experimentation laid
Coolant (gm) 1.970 0.150 0 to endorse a better performance for the MQL, which enables a
Cutting tool (gm) 0.150 0.140 0.150 significant diminution in both tool wear and surface roughness
Disposal (gm) 1.970 0.150 0 when compared to other conventional techniques. Yazid et al.
[28] turned Inconel-718 to evaluate the effect of working
350 Int J Adv Manuf Technol (2020) 109:345–376

Table 3 Environmental impacts

and benefits associated with MQL Impacts TFC MQL CA % Savings (MQL)
[18]
Global Warming (kg CO2-eq) 0.38 0.30 0.21 21
Eutrophication (kg PO4-eq) 5.26 × 10−4 1.01 × 10−4 8.23 × 10−5 81
Human toxicity (DAILY) 3.11 × 10−8 4.06 × 10−9 3.28 × 10−9 87

parameters on the surface properties. The machining was per- tool interface, tool wear, and surface finish. The optimal op-
formed under dry, flood as well as near dry machining condi- erating parameters were chosen with the assistance of the
tions. The MQL fluid flow rates were varied for two different Taguchi method. The significant improvements in roughness
levels 50 ml/h and 100 ml/h, respectively. The SEM images values have been recorded when using soluble oil under the
gathered from the workpiece after machining reveal many MQL system. Besides, it was possible to obtain a significant
deformations and changes in the microstructure. It was no- improvement in the machinability characteristics. Sivalingam
ticed that MQL could be useful for surface integrity charac- [32] carried out tests under two different cooling regimes,
teristics. Ali et al. [29] studied different parameters including namely dry and MQL reinforced with molybdenum disulfide
chip thickness ratio and cutting temperature to investigate the and graphite nanopowders at 0.2 wt% concentrations in turn-
MQL effects. Responses such as flank wear as well as cutting ing of nickel alloy 718 with ceramic cutting tools. A remark-
forces were analyzed. The work was conducted on medium able decline in flank wear, surface roughness, and vibration
carbon steel at a pre-determined speed and feed combinations. was recorded, which facilitate the improvement of environ-
The analysis of the results proved that MQL provides much mental sustainability due to the use of nanoparticle-based
better features. Improvements in productivity were also re- MQL process. Amrita et al. [33] executed several trials to
ported when considering all design-related costs. Ozcelik analyze the performances of mist and flood cooling while
et al. [30] worked the impact of the vegetable-based cutting the turning process of AISI 1040 material. The misting fluid
fluid (VBFC) blend of two distinct oils (i.e., canola and re- was enriched with nanosized particles to improve the lubricat-
fined). It includes the high-pressure additives mist and com- ing properties of the base fluid. The data was measured as the
mercial type of cutting fluids (i.e., mineral and semi-synthet- interface temperature, cutting forces and tool wear. Immense
ic). Machining operations were performed with various ma- improvements were recorded in terms of cutting temperature,
chining parameters on AISI-304 L. The results revealed that cutting forces and tool wear when using nanoparticle enriched
the canola cutting fluid containing 8% of EP additives allows fluids.
improving the surface quality. It was concluded that the Liu et al. [34] explored the wear resistance of cutting tools
VBFC could replace the mineral and semi-synthetic based during machining titanium-based alloys. Several input vari-
cutting fluid and allows it to decrease the health hazards. ables such as coating types and cooling environments (dry
Borkar et al. [31] performed experiments using the MQL pro- and MQL) were tested. It was reported that the (nc-AlTiN)/
cess assisted by the soluble oil. Flood cooling and dry machin- (a-Si3N4)-coated tool under MQL exhibited better perfor-
ing were utilized to develop a relationship between the work- mance than (nc-AlCrN)/(a-Si 3 N 4 )-coated tool in the

Fig. 4 The impact of several

cooling regimes on ecology and
worker health [20]
Int J Adv Manuf Technol (2020) 109:345–376 351

machining of Ti alloys. Hadad and Sadeghi [35] executed focused on determining the usual input parameters while ma-
turning tests to highlight the influence of different input vari- chining Titanium 5553 alloy. The comparisons were made
ables (i.e., the nozzle position) when applying some cooling between the cryogenic and MQL environment. It was ob-
regimes, namely dry, wet, and MQL while machining AISI served that the machining of titanium alloy with liquid nitro-
4140 steel. The cutting fluids were considered water-based gen reduces the cutting force by 30% when it is compared to
ester, which mixed in a ratio of 10:1. The rate of fluid flow the other techniques. In addition, it was found that the nose
was kept constant at 30 ml/h, while the pressure of the air was wear of cutting tools become better in cryogenic cooling.
fixed at 3 bars. The feed rate was imposed as 0.09 and However, a higher surface finish was accomplished using
0.22 mm/rev. The importance of the MQL nozzle position the MQL technique due to a better penetration of the MQL
was highlighted, as well. It reveals drastic reductions in the mist.
interface temperatures as well as cutting forces and surface Paturi et al. [43] carried out trials to survey the impact of
roughness when using the oil mist process. Hence, tempera- MQL application on the surface finish of nickel alloy 718
ture reduction as high as 350 °C was reported. Sanchez et al. while the turning. The composition of the cutting fluid
[36] performed experiments in turning of SAE EV-8 steel by consisted of an ester-based oil mixed with tungsten disulfide
employing the triangular geometry cemented carbide cutting particles by 0.5% weight. The influence of different process
tool and using the conventional cooling, minimum quantity parameters was studied using several statistical tools. The re-
cutting fluid (MQCF), MQL and pulverization techniques. It sults showed a 35% improvement with solid lubricant-based
was reported that the performance of the machining operation MQL in the surface quality when compared to the MQL pro-
could be increased with the cutting fluid applications. Ramana cess without nanoadditives. Sharma et al. [44] showed the
et al. [37] worked to optimize the process parameters of ma- importance of cutting fluids during cutting operations in terms
chining titanium grade 5 alloy. The Taguchi principle was of cutting temperature and chip morphology. In order to safe-
applied for the experimental design and the flank wear was guard the worker’s health as well as the environment, the need
chosen as the primary measured response. The results reveal for a particular type of cutting fluids was emphasized. It was
that the MQL process with uncoated tool shows better ma- recommended that fluid with better thermal and tribological
chining characteristics as compared with the other conditions. properties is needed. The use of nanofluids was shown to be
Sharma and Sidhu [38] machined the AISI D2 steel to evalu- indispensable. The fluid preparation was done by mixing alu-
ate the performance of both MQL and dry machining tech- mina nanoparticles with the base fluid using an ultrasonic
niques. Vegetable-based oil was used as a lubricant for devel- agitator. The nanofluid was sprayed on the cutting zone during
oping the process of sustainability. The insert material used the turning of AISI 1040 steel. Much better results were re-
for turning was tungsten carbide. The results showed that corded for the surface texture using nanofluid MQL when
MQL permits to improve surface roughness and tool wear. compared against traditional techniques. Akhtar et al. [45]
The minimal flow technique not only improves the machining prepared nanocutting fluid by mixing alumina and TiO2
process but also makes the process more sustainable. Deiab nanosized particles in various proportions such as 0.05, 0.15,
et al. [39] investigated the influential characteristics of several and 0.3 wt.%. The prepared solution was used in MQL tech-
cooling techniques on different parameters while turning tita- nique while machining AISI 1018 alloy using carbide tools. It
nium Ti-6Al-4V with uncoated carbide tools. Relative effects was concluded that the prepared solution had provided better
on the roughness and energy consumption were recorded. The spreadability and thermal conductivity, leading to a significant
use of rapeseed oil was observed to improve the process of reduction in cutting temperature and surface roughness. As a
sustainability. Abhang and Hameedullah [40] conducted turn- result, the amount of coolant has been remarkably diminished
ing experiments on EN-31 steel, and the surface properties with the use of nanofluid-MQL and the turning process per-
were studied based on several input parameters. It was con- formance has been improved. In another study performed by
cluded form statistical analysis that the cutting speed, feed Chetan et al. [46], machining tests conducted on Nimonic-90,
rate, depth of cut, insert nose radius, and environment have Ni-based alloy, and Ti-6Al-4V, titanium-based alloy, respec-
impact on surface roughness. In some recent works, Rahim tively. The turning tests were made in order to make compar-
et al. [41] conducted different experiments by utilizing orthog- isons between dry and MQL conditions for sustainable im-
onal cutting of AISI 1045 steel. The cutting environment was provement. For sustainability, the MQL conditions were con-
dry, and synthetic esters based MQL. The results from these sidered by using sunflower oil in water due to its biodegrad-
two conditions were investigated to determine the best cutting able properties. Moreover, the use of a biodegradable emul-
temperature, chip thickness, tool-chip thickness and cutting sion led to outstanding results for wear of cutting tool and
force. It was reported that the synthetic ester-based MQL re- cutting force when turning of titanium alloy.
duces cutting temperature by up to 30% and cutting force by Kumar et al. [47] performed machining experiments while
up to 28%. It also allows enhancing the chip thickness in turning AISI 4340 steel with CBN cutting tool. The process
comparison to dry cutting environment. Sun et al. [42] parameters with a higher impact as speed, feed, hardness, etc.
352 Int J Adv Manuf Technol (2020) 109:345–376

were considered. The analysis of the results was performed by results indicated that the MQL permits to improve the re-
applying ANOVA calculations, while the mathematical sponses more efficiently as compared to dry machining. The
models were determined using regression models. It was dem- MQL role over the HSM application is highlighted because it
onstrated that the MQL provides superior results in terms of may generate extra oxygen in the middle of the chip-tool
surface roughness. Bagherzadeh and Budak [48] studied four interface. Therefore, the tool life results have been improved.
kinds of cooling strategies to enhance the hard turning of Thamizhmanii and Hasan [58] performed another research
titanium and nickel base alloys. They used carbon dioxide using a vertical milling machine. The process parameters were
delivery system, modified carbon dioxide nozzle, a combina- varied within different predefined levels, and the milling was
tion of carbon dioxide with MQL and CMQL techniques in performed using a hardened cobalt tool. The efficiency of
order to generate good output variables (i.e., surface rough- MQL was tested keeping constant the flow rates of 12.5, 25,
ness, tool wear, and temperature). They revealed that the and 37.5 ml/h and using biodegradable vegetable oil.
CMQL is a welcome technique that enhances the tool life up Different flow rates of the MQL had influenced the tool wear
to 60% and 30% in the machining of Ti6Al4V and Inconel and surface roughness up to approximately 33% and 30%,
718, respectively. Furthermore, it can generate better surface respectively. It was also shown that the tool life results obtain-
quality in contrast with other systems verified. The employ- ed using the MQL conditions were approximately 44% better
ment of MQL in turning process improves the machining than the dry machining. Thepsonthi et al. [59] investigated the
performance especially with regard to tool war and surface metal cutting efficiency of the MQL process while milling
finish of the cut surfaces in comparison to dry medium and ASSAB DF3 steel with a hardness of 51 HRC. The experi-
flooding cooling. In addition, the performance of base fluid ments were performed using three different cooling regimes
based MQL can be improved further with the addition of with a TiAlN-coated milling insert. The variations in the
nanoparticles. It has been shown that MQL gives good results speed, feed, cutting depth as well as in the cooling condition
especially in the turning of steels compared to super alloys, were made to obtain superior outputs parameters. The findings
which are difficult-to-machine materials. Therefore, MQL in prove that the MQL process offers better results when com-
turning operations can be an effective option to dry and flood pared to other cooling strategies. Besides, the investigation
cooling. The main machining works focused on MQL have demonstrated that most of the negative effects on the environ-
been tabulated in Appendix Table 6. ment can be eliminated with the use of MQL. Li and Chou
[60] performed milling operation on SKD 61 steel by using
3.2 Effectiveness of MQL in milling operations uncoated carbide tool in dry and MQL conditions. Small-tools
with a diameter of 600 μm were used. The milling process
Many researchers studied the turning process; however, ex- was carried out imposing a speed between 20,000 and
tensive work has been focused on the milling process as well. 40,000 rpm, and the cutting depth was kept constant at
Some studies are discussed in this section. For example, Sun 0.3 mm. The feed rate, air supply rate, as well as the lubricant
et al. [55] observed the reaction of titanium (grade 5) alloy via supply rates were also varied. The observations with regard to
a carbide tool. The different cooling regimes were developed burr formation, surface texture, and tool wear were evaluated.
considering the MQL approach in order to detect the behavior It was proved that the MQL helps to improve the above char-
of the tool life. It was shown that the MQL process proved acteristics and allows a higher quality manufacturing process.
reliability due to its combinational aspects produced by its Silva [61] has chosen various different compact graphite cast
cooling and lubrication functions. Lacalle et al. [56] investi- irons as work material. The cutting tool geometry and its coat-
gated the role of the cutting fluids on various machining out- ing, cutting environment including dry and MQL and milling
puts. Experiments were conducted while milling aluminum parameters (cutting speed and feed rate) were considered as
alloys. The relative impacts of MQL and flood cooling tech- inputs, while the tool life, wear behavior, surface quality and
niques were compared. The MQL flow rate was maintained at electric current consumption was taken as outputs.
0.06 ml/min while using a constant pressure of 10 bar. The Comparisons were made with the classical cooling techniques
application of spray cutting fluid made significant progress in to demonstrate the effectiveness of MQL process. It was con-
reducing both tool wear and cost together. Liao and Lin [57] cluded that with MQL medium, perfect tool life and less elec-
conducted high-speed machining (HSM) experiments with a tric current consumption were achieved in 200 m/min cutting
vertical milling machine. The machining trials on a mold steel speed. Taylor et al. [62] conducted a group of experiments in
NAK80 were realized using dry and MQL conditions. The order to compare the traditional cooling techniques with the
values of tool wear and milling forces were calculated based MQL approach when milling of tool steel that has 53 HRC
on the input parameter variation. The machining speed and hardness. While the life of the milling tool was 73 min during
feed rate were varied in the ranges 300 to 500 m/min and dry cutting, this time was increased to 120 min when MQL
0.1 to 0.20 mm/tooth. Likewise, the axial and radial depth of strategy was applied. As a result, the tool life was improved by
cut was set as 0.3 and 5 mm, respectively. The experimental 60% with the MQL. Zhang et al. [63] compared the relative
Int J Adv Manuf Technol (2020) 109:345–376 353

effectiveness of dry and MQL techniques. The MQL fluid- In milling proces, the employement of cutting fluid is not as
applied was biodegradable oil and was mixed in small quan- common as in a process turning, due to the fluctuations (be-
tities with a large proportion of water. Milling test was per- cause of the intermittent cutting) in temperature leading to
formed on Inconel 718 alloy. The machining of this alloy may thermal cracks in the cutting tool. For this reason, dry cutting
be greatly influenced by the addition of a mist cooling process, is the ideal choice when high temperatures do not cause prob-
which further enables the superior performance of the machin- lems during milling process. When milling hardened steels
ing outputs. Shahrom et al. [64] performed milling process on and superalloys at high speed, high temperatures occured at
an aluminum workpiece within three distinct ecological con- the machining area are the main reason for rapid insert wear.
ditions (wet, dry, and MQL). The actual operating variables, Therfore, it can be clearly said MQL (also called as near-dry
i.e., cutting speed, feed rate, and depth of cut were varied by machining) is the best alternative option in the intermittent
applying four predefined levels of them. It was reported that cutting operations. Appendix Table 7 presents the literature
MQL produced better product quality in comparison to the review of MQL in milling processes.
traditional machining. Moreover, it revealed that the error be-
tween experimentation and calculated responses is consider- 3.3 Effectiveness of MQL in grinding operations
ably higher by applying wet machining in comparison to
MQL machining. Do et al. [65] realized hard-milling trials The grinding operation is a vital part of the manufacturing
AISI H-13 steel. Some statistical tools were utilized to analyze industry since it is the final process for workpieces that require
the various studied responses. The use of the dry medium, high surface quality and dimensional accuracy. In addition,
MQL, and 2 wt% SiO 2 nanoparticles with the size of the need for eco-friendly production alongside ever-
100 nm incorporated in MQL was performed by varying dif- increasing disposal costs is one of the most remarkable chal-
ferent levels of speed, feed, and other vital parameters. A low lenges faced by this industry [70]. For these reasons, MQL has
flow rate of cutting liquid (90 ml/h) was applied by MQL been a chance for grinding operations and has been used with
approach. The improvements in surface roughness were re- success on several different grinding processes. For instance,
corded at a satisfactory level as a result of using the MQL Silva et al. [71] used the MQL practice on ABNT 4340 steel
process. It enables ecological as well as financial viability by using an aluminum oxide wheel. They compared MQL
when using the MQL technique. Wang et al. [66] performed performance with traditional method. Various tests were per-
the milling of Inconel 182 alloy using different types of cut- formed to find out the optimum lubricant and airflow rate. Dry
ting inserts. Different comparisons between the PVD-coated and MQL machining is considered a better option than the
as well as an uncoated insert were done for some variable traditional machining. Moreover, a special nozzle is required
nozzle locations relative to the cutting zone. The uncoated to vary the fluid application as well. The eco-friendliness of
inserts failed the test in milling of Inconel 182 alloy as a result this process was improved by applying a minimal quantity of
of their extremely high wear rates. Thus, based on the exper- biodegradable oil. The efficiency of the MQL technique was
imental work, the importance of using coated tools was related to the surface finish of the machined workpiece. The
highlighted. Priarone et al. [67] observed and reported the role MQL allows better outcomes associated with superior lubric-
of cooling techniques of different responses such as surface ity. It permits the reduction of frictional forces. A proper lu-
quality and sustainability etc. A titanium-based alloy was bricant with superior properties prolongs the surface integrity
employed in the experimental work. The results proved that characteristics. Tawakoli et al. [72] explored the role of MQL
MQL is a much better alternative. Soman et al. [68] conducted over the forces and surface characteristics. Many fluids were
a series of experiments in order to detect the superior process used for conducting the experiments, while comparisons were
parameters and a comparison between the dry, flood, and made against the dry cutting conditions. Here, three different
MQL was implemented in milling Monel 400 alloy. types of grinding wheels were engaged in this process. It pro-
Besides, the measured outputs (i.e., roughness, wear rate, vides excellent results when the SH integrated with the MQL
etc.) were optimized with respect to the input parameter set- technique. Liao et al. [73] analyzed the effect of nanoparticle
tings. MQL showed much better results when compared to enriched fluid for both MQL and flood conditions during
conventional techniques. Jang et al. [69] studied the possibil- grinding of titanium grade 5 alloy. In addition, the water-
ity to obtain environmental conscious manufacturing (ECM) miscible cutting fluid was applied to get relative comparisons.
for milling processes. The amount of cutting fluid was mini- The morphology of the cut surface and wheel loading were
mized by applying the MQL process. The input parameters kept under the observation. The application of nanoparticles in
were varied to find their effects on the output responses. the system allows noticeable reduction in the roughness asso-
Firstly, pilot test was conducted to decide the ranges of vari- ciated to lower applied loading on the grinding wheel. It is
ous input parameters that permit to implement a model related also found that the nanoparticles produce a rolling effect.
to the cutting energy. ANN technique was employed to enable Hence, it can reduce the thermal conductivity of the cutting
the model generation. fluid which definitely leads to some improvement on the
354 Int J Adv Manuf Technol (2020) 109:345–376

machining performance. Obviously, the use of the MQL ap- that the grinding forces, temperatures and roughness may be
proach can improve the measured machining outputs and en- reduced when using the MQL technique. Moreover, the crest
vironment features. flattening phenomenon was not noticed with the usage of
Sadeghi et al. [74] carried out some comparative studies for MQL. Setti et al. [80] examined the potential of Al2O3
the detection of the ability of different coolants. The compar- nanofluid into MQL conditions in order to enhance the grind-
isons were made between synthetic esters, mineral, and vege- ing operation of titanium (grade 5) alloy. The outcomes were
table oils. The results prove the utility of the MQL approach validated against the existing techniques. Zhang et al. [81]
when comparing to dry as well as flood cooling techniques. performed comparative research among different types of lu-
Qu et al. [75] performed grinding tests using nanoparticle- brication oils such as rapeseed oil, castor oil as base fluids.
based fluids. The carbon nanosized particles were mixed using The comparisons were made against liquid paraffin consider-
an ultrasonic vibrator. The main goal was to explore the po- ing both cooling and lubrication properties. The grinding of
tential employment of carbon nanoparticles into the pure- steel was initiated by using the MoS2 nanoparticles. Later, the
cutting fluid. The experiments were performed on carbon relative comparisons of these cooling regimes were conduct-
fiber-reinforced ceramic matrix material which is very diffi- ed. The grinding forces were measured and compared for
cult to cut. The experimental finding showed that nanocutting different fluid viscosities. In addition, the surface roughness
fluid enhanced by carbon nanopowders can permit to decrease evolution was also considered (refer Figs. 5 and 6). It reveals
the surface roughness and forces as well as the heat-induced that the palm oil achieved the best lubrication in conjunction
surface damage. Kalita et al. [76] reported important observa- with nanofluid jets that are associated with the carboxyl
tions while using nanoparticle enriched lubricants in combi- groups identified in the palm oil. Setti et al. [82] performed
nation with the mist cooling technique. The Molybdenum research using nanofluids as main cutting fluids, while alumi-
disulfide (MoS2) nanoparticles were used for this purpose. na and copper oxide nanoparticles were added in various por-
Their size was less than 50 nm. The grinding was carried out tions by volume. Water was considered as base fluid during
on cast iron and EN 24 steel by applying nanomist. It was grinding of titanium (grade 5) alloy. The process was initiated
observed that the nanoparticle-based technique enables much in the presence of a mist cooling technique. A surface profile-
better results as compared to the other techniques. The results meter was used to detect the surface properties of the ma-
were improved considerably by increasing nanoparticle con- chined surfaces as well as their integrity (i.e., details presented
centration. In addition, soybean and paraffin based-nanofluid for surface roughness in Fig. 7). It was concluded that the use
exhibited superior results for EN 24 steel and cast iron, respec- of alumina nanoparticles with various proportions into base
tively. Setti et al. [77] done experimental studies in turning of fluid could play a leading role. It may drive the frictional
titanium (grade 5) alloy assisted by the nanoparticle enriched forces as well as the surface roughness data. On the other
fluid using the MQL strategy. The experimental design was hand, Fernandes et al. [9] done an assessment for MQL and
built with the assistance of Taguchi’s arrays to better control conventional cooling and they reported that conventional
the surface quality and forces. The Al2O3 nanoparticle was cooling was more useful than MQL since a thermally induced
mixed with water and the results were compared to the tradi- harm was not seen in workpieces. In addition, they claimed
tional techniques. Consequently, the rolling effect developed that clogging problem in the grinding wheel surface during
by the nanoparticles may cause a ball-bearing process. It may MQL occurred. In grinding of alumina with diamond grinding
enable a reduction in the frictional forces, which inevitably wheel, Lopes et al. [83] reported that the best surface quality
entail a lower cutting force. Moreover, it was reported that was achieved by using the traditional cooling, and then MQL.
surface roughness decreases with higher concentration of In recent years, Rodriguez et al. [84] noticed that flood cooling
nanoparticles. Oliveira et al. [78] used a vitrified CBN wheel was better than traditional MQL application in terms of most
under MQL in the grinding operation on AISI 4340 steel. quality indicators. In grinding processes, although the MQL
Additionally, the air stream concentrated was released on the environment offers better results of surface quality and friction
cutting zone in order to remove away the chips from the cut- coefficient, temperature, and force as compared to dry cutting,
ting area and to eliminate the cutting fluid. The outcomes of it has lagged behind conventional cooling, especially in grind-
the study were the work material roundness error, surface ing of some materials such as hardened alloys. In addition, in
roughness, wheel wear, and acoustic emission. The results recent years, nanocutting fluids prepared by adding solid
obtained were found positive when using this technique. nanoparticles to the base cutting fluid into MQL have emerged
However, the MQL not only improves the process of econom- as a sustainable alternative to conventional cooling, in partic-
ic performance but also permits to reduce the usage of cool- ular as it helps for evacuating the heat from the machining
ants. Balan et al. [79] conducted experiments on Inconel-751 region. The in-depth literature related to the grinding process
to enhance grinding operation performance. It was concluded has been introduced in the Appendix Table 8.
Int J Adv Manuf Technol (2020) 109:345–376 355

Fig. 5 Surface roughness under various operating conditions [81]

3.4 Effectiveness of MQL in drilling operations local cutting temperatures. As a result, the tool life was re-
duced considerably. The TiAlN- and TiN-coated drill may
Drilling is considered as the most used machining process in bring beneficial features (i.e., advanced hot hardness, oxida-
various sorts of industrial applications. The hole quality, tool tion equality and lower heat conductivity). These features can
wear, delamination of workpiece, and surface roughness are help to save the drill from any wear and tear. The uncoated
the relevant machining indices affected by the various ma- drill should not be used for drilling of deep boreholes in dry
chining parameters and conditions such as dry, MQL, flood, conditions because this will tend to wear out very quickly.
etc. Therefore, in this section, most work reported on drilling Subsequently, it is assumed that the MQL technique with a
operation under MQL conditions was presented. For instance, coolant having less viscosity and better heat capacity produces
Heinemann et al. [91] investigated the role of mist lubrication considerably longer life.
that helps to enhance the life of a drill tool. The primary issue Bhowmick et al. [92] done a research to analyze the impact
affecting the process efficiency is related to the external sup- of flood and MQL under drilling of AM60 Magnesium alloy.
ply of fluid. It was proved that the fluid supply and MQL type They made comparative studies among flood and MQL. The
could have a tremendous effect on the drill tool life. When the output parameters namely thrust force and average torque
drilling was conducted under dry conditions, the absence of during a drilling operation were considered. The H2O -MQL
any cutting liquid led to friction growth that generates higher distilled water and FA-MQL based fluid (fatty acid) were used

Fig. 6 a Coefficient of friction. b Specific grinding energy for the nanoparticle jet MQL grinding experiment with four types of base oil [81]
356 Int J Adv Manuf Technol (2020) 109:345–376

in the cutting temperatures was achieved. It was shown that

the oil forms a protective coating around the workpiece at
cutting zone. In another study performed by Rahim and
Sasahara [94], comparative studies between the palm-based
oil and synthetic esters were conducted. The test was made
while drilling Inconel 718 alloy (see details of parameters
process in Fig. 8). Apart from improving machining outputs,
palm oil can aid in improving the microhardness of the work-
piece. Kuram et al. [95] explored the efficiencies of different
green fluids when drilling several materials. The experiments
Fig. 7 Variation in average surface roughness values under different were designed using the Taguchi L9 arrays combined with the
environments (error bars represents a standard error in data) [82] regression analysis. The comparisons with sunflower oil in
crude and refined forms were made to detect the best machin-
as coolants. The flow rate was kept constant (10 ml/h); then, ing performance. The spindle speed variations, depth, and
the results obtained were compared against mineral oils. The feed rate were conducted to obtain the relative effects on the
outcomes proved a reduction of adhesion amount of magne- drilling force, which later enable better hole quality. Biermann
sium over the tool and only a small amount of built-up edge et al. [96] studied the distribution of heat while machining
was noticed. This significant reduction led to much-lowered aluminum alloy (EN AC-46000). Carbide drills were used
values of thrust forces and torque. The maximum temperature for the experimentation together with a single lip procedure.
reached on the workpiece while using MQL technique was The solid carbide drills promote favorable working condi-
found much lower with respect to a typical process. tions. It allows a higher efficiency, which leads to profitable
Furthermore, it can provide uniform torque with much stable manufacturing. Besides, the use of MQL approach may fur-
behavior during the drilling. It presented an improvement in ther enhances the process in terms of cost and environmental
the hole quality. Rahim and Sasahara [93] studied the effects effectiveness (making it eco-friendly).
of different type lubricants by applying the MQL technique Chatha et al. [97] studied the working efficiency using
while drilling the titanium (grade 5) alloy. Synthetic ester- different lubricating/cooling methodologies including both
based oil and palm oil were engaged during experiments. It conventional and nonconventional ones. The use of nanopar-
reveals a much shorter tool life in dry drilling caused by the ticles was proposed to elucidate their effectiveness. The role of
detrimental chipping. The palm-based oil efficiency was dem- input parameters vs measured outputs such as the roughness,
onstrated by the fact that a reduction in thrust force as well as

Fig. 8 Plastic deformation layer

variations under different cooling
regimes [94]
Int J Adv Manuf Technol (2020) 109:345–376 357

Fig. 9 The average surface

roughness (Ra) under dry, flood,
pure MQL and nanofluid MQL
drilling at spindle speed of 30 m/
min [97]

tool wear, and forces were highlighted. HSS drills were used along with the usage of argon gas. Further, the cryogenic
to machine aluminum 6063 alloy. The flow rate used in the aplications are believed as efficient way for improving the heat
MQL process was maintained at 200 ml/h with a compressed distributing and machinability characteristics [100].
air flowing at a pressure of 70 psi. The nanoparticles were Generally, nanofluid enables the formation of a new fluid.
mixed with base fluid (made of soya bean oil) to use into It can be done by addition of particles having size lesser than
MQL system. The employment of such advanced cooling 100 nm to a basis liquid. They have the role to improve certain
strategies improved the tool life by increasing the number of properties [101]. These additives can be divided into several
holes drilled. Moreover, the burr formation was also reduced categories such as metallic, non-metallic, ceramic based, car-
using MQL technique along with the improvement in the hole bon based etc. [102]. Several benefits of nanofluids among
quality as seen in Fig. 9. In summary, the success of the dril- various practices are listed as following [103]:
ling operation is significantly impacted by the machining en-
vironment. Dry cutting is not strongly recommended for dril- & High rate of heat transfer as a result of a higher specific
ling. In addition, the MQL application as an option to dry surface area.
environment is critical, since it does not cause environmental & Highly stable when dispersed.
concerns and brings machining performance close to conven- & Energy savings spent in condensing pure-fluid because
tional cooling in a drilling operation. The Appendix Table 9 nanofluids may extend the required heat carrying features.
presents the survey details of MQL drilling process. & Low contact angle and heat carrying features of a surface
are controlled by the modifying the concentrations of
nanoparticles.

4 MQL upgradations with nanofluids Illustrations of various practices that use the nanofluid
and application techniques method to expand its substantial features including thermal,
rheological, and stability are obtained through various litera-
The increase of heat dissipation is a crucial necessity during the ture survey [104]. This section is mainly focused to present a
cutting processes. It could present useful outcomes regarding comprehensive literature survey of publications, which are
the energy consumption, tool lifespan, and manufacturing ca- related to the issues such as preparation, characterization, sta-
pacities. The known ways to increase the heat distributing for bility, thermal and rheological properties, improvements in
numerous industrial functions has been concentrated on the machining quality characteristics, and challenges of
heat exchanging zone modification. Yet, there are still concerns nanocutting fluids.
about its thermal capability. As a result, there is a huge need to
improve the cutting characteristics. Scholars all over the globe
have proposed numerous procedures. The technologies such as 4.1 Techniques of nanocutting fluid preparation
MQL or cryogenic cooling are highly friendly in respect to
environment. Although the dry machining can be exercised In order to achieve the optimum thermal properties, two major
for total stoppage of cutting fluids usage, it shows poor machin- parameters, namely, durability and stability, need to be con-
ing characteristics [98]. Kamata and Obikawa [99] investigated sidered. Achieving lower sedimentation velocity of
another conscious technology known as mist cooling. It has the nanoadditives is an essential requirement to ensure the
advantage of high penetration due to the use of compressed air nanofluid’s stability. The sedimentation velocity can vary
358 Int J Adv Manuf Technol (2020) 109:345–376

proportionally with the square of nanoadditive radius accord- 4.2 Characterization of nanocutting fluids stability
ing to the Stokes law given in Eq. (1):
The nanocutting fluids resulted from the suspension of
2R2

Vs ¼ ρp −ρm g ð1Þ nanoadditives into the base cutting fluid are characterized
9μm by parameters such as nanoadditive types, base fluid, ad-
ditional additives and scale. During the nanofluid
where vs is the velocity of sedimentation, R represents the aver-
manufacturing process, the fluid composition design is
age radius of nanoadditives, μ is the viscosity of the base fluid
made by taking into account the required thermal, tribo-
viscosity, ρp is the density of nanoadditives, and ρm is the density
chemical, physical, and rheological properties. Here, it is
of base fluid. However, using a lower particle radius leads to a
compulsory to achieve the resultant nanofluid accordingly
decrease in the sedimentation velocity, while the surface energy
to the functional requirements of each nanofluid type. Due
of the nanoadditives is increased which can result in
to the major issue of clogging, there is a need to ensure the
nanoadditive aggregation. Thus, selecting an optimal value of
presence of repulsive forces between these nanoparticles in
the nanoadditive size and performing homogeneous dispersion
order to increase their dispersion time [112]. Two princi-
are highly important to avoid both higher sedimentation velocity
ples have been studied for establishing a high suspension
and occurrence of nanoadditives aggregation [105, 106].
quality for the nanoadditives into the base oil, namely,
There are two main techniques for nanofluid preparation:
diffusion and zeta potential. The first principle is the dif-
two-step and single-step. The two-step technique means
fusion, which ensures that the nanoparticles remain evenly
manufacturing and dispersion, while the single-step technique
suspended in the solution. The second principle is mainly
depends on making both of them concurrently. In regard to the
focused on obtaining a better zeta potential value, which
two-step technique, this is more suitable during dispersion of
offers a repulsive force among the nanoadditives [113].
oxide particles and carbon nanotubes. It shows great potential
There are three main methods that offer a high suspension/
results for metal-nanoparticles. Even, this technique includes
stability performance in order to avoid the nanoadditive ag-
two steps to disperse the nanoadditives into the base fluid; it is
glomeration, clogging, and sedimentation. The three main
simpler when comparing to other technique. Yet, several
methods are as follows:
problems such as nanoadditive agglomeration are noted.
Some specific methods are used to resolve the previously
& Surfactant: The use of surfactants to stabilize nanoparti-
mentioned problem using ultrasound, and/or high shear ap-
cles dispersed in nanofluid is one of the first preferred
proaches. The two-step technique can fit more volume con-
ways. In such a situation, the surfactant not only improves
centration values which is in turn of 20% [107, 108]. In terms
the stability of the nanofluid but also has an incentive on
of the single-step technique, drying, storage, and transporta-
hydrate formation [114]. Thus, the suspension of
tion of nanoadditives are included. Hence, a stable and durable
nanoadditives into the base fluid can be improved; how-
nanofluid can be achieved as nanoadditive agglomeration and
ever, the selection of optimal amount of surfactant is an
sedimentation may be avoided. However, the higher efficien-
important factor because it can affect the resultant electro-
cy observed on the single-step technique, in terms of
static repulsion. Another limitation of this technique is the
nanofluids’ stability and durability, cannot fit well when the
difficulty in applications associated with higher tempera-
applications of large volume concentration are required [109].
ture as the repulsive forces can be damaged [115]. Here,
Nanoadditive suspension and depressiveness greatly influence
various examples of surfactant have been used such as;
the characteristics of the fluid. Such dispersions can be
sodium dodecyl sulfate, dodecyl trimethylammonium bro-
achieved using an ultrasonic machine following by mixing.
mide, and polyvinylpyrrolidone [116].
By using a magnetic stirrer, the complete dispersion of
& pH control: The nanofluid pH can control the stability and
nanoadditives can be achieved. Furthermore, the processing
may improve the thermal conductivity that are related to
time for each previous step depends on the percentage of
the electro-kinetic properties. Using a simple chemical
nanoparticles [110]. The nanoadditive concentration (%
treatment technique is possible to obtain conversion for
weight) into the base cutting fluid is calculated using the Eq.
the nanoadditive shape, which results in higher surface
(2):
discharge density, electric repulsion force, and zeta poten-
%of weight concentration ¼
nanoadditive weight
x100 tial value. Thus, agglomeration, clogging, and sedimenta-
nanoadditive weight þ the base fluid weight
tion effects can be decreased, and high suspension quality
ð2Þ of the resultant nanofluid can be accomplished [117, 118].
It has been noted that during the dispersion of Al2O3 nano-
Another alternative technique for dispersal of nanopowder
particles into water, the base fluid agglomeration size is
into the basis liquid is nanoadditive synthesis using chemical
decreased at pH level of 1.7. However, an increase of
precipitation or organic reduction [111].
agglomeration size has been noticed at a pH level of
Int J Adv Manuf Technol (2020) 109:345–376 359

techniques to check the process stability. Table 4 shows the

suspension stability at different zeta potential levels [123].

4.3 The thermal and rheological nanocutting fluid

properties

It was previously observed that thermal conductivity evolved

when different nanopowder types, sizes, and volume fraction
percentages were inserted (details shown in Appendix
Table 10). Various analytical models have been performed
to express the nanofluid thermal conductivity. The Maxwell
equation [137] shown in Eq. (3) can predict the thermal con-
ductivity depending on the base fluid’s thermal conductivity
Fig. 10 The inter-particle distance versus the total nanoparticles energies (Km), the nanoadditive thermal conductivity (Kp), and the
at different PHs [118] nanoadditive volume fraction (Ʋp), while the resultant thermal
conductivity is (Ke).
7.66 [119]. Furthermore, another study provided the ef-
fects of pH on the Vander Waals attraction and electrostat- ð3Þ
ic repulsion energies (total energy) at different inter-
particle distance using metal oxide nanoparticles.
Moreover, it can be observed that the total energy is in- Another modified model has been obtained for calculating
versely proportional to the pH values at lower levels of the nanofluid thermal conductivity as shown in Eq. (4) [137]:
inter-particle distance; however, no significant effect of
pH can be observed at higher levels of interparticle dis- ð4Þ
tance as shown in Fig. 10 [118].
& Ultrasonic vibrations: This technique aims to break down
the agglomerations among nanoadditives. It reveals prom-
ising results in term of process stability. Nevertheless, op- where ρp, Cp, T, Ƞ, and R are the nanoadditive density,
timizing the processing time is required because it lead to a nanoadditive specific heat, temperature, viscosity, and
fast clogging and sedimentation of nanoadditives [120]. nanoadditive radius.
The ultrasonic disruptor is the most popular apparatus On the other hand, the use of the hot-wire technique was
used for ultrasonic vibration to disperse the nanoadditives employed to estimate the values of the thermal conductivity,
into the base fluid. The applied mechanisms during the and it is called transient line heat source method [138]. In
ultrasonic vibration include three stages to ensure fully addition, the nanofluids have shown promising results to en-
process stability and decreasing the clogging and agglom- hance the heat transfer coefficient. The investigation of the
eration size [121]. cooling capabilities of nanofluids when grinding operation
of Ti-6Al-4V alloys (nanofluid heat transfer coefficient/base
fluid heat transfer coefficient) for different nanoadditives
It was mentioned [122] that several instrumentation tech- types and volume fractions was made by Ibrahim et al.
niques such as the sediment photography capturing, UV–Vis [139]. Furthermore, two analytical models have been devel-
spectrophotometer, TEM, SEM, and scattering of light are oped to predict another heat transfer indicator, which is the
employed to assess the nanofluid suspension performance. specific heat. The analytical model that is based on the nano-
However, the zeta potential analysis is the most popular particle volume fraction has been shown in the Eq. (5) [140].

Table 4 The suspension stability at different zeta potential levels [123] ð5Þ
Z potential absolute value Stability status
where Cbf is the base fluid’s specific heat, and C is the
0 No stability at all nanofluid specific heat.
14 Very less stability Another effective property in terms of nanofluid dynamics
28 Medium stability is the viscosity, because it is an important factor for the heat
42 Fair stability with possible settling transfer [141]. Furthermore, the nanofluids rheological behav-
56 Good stability ior can be obtained through investigating its effects. Several
analytical models have been implemented to calculate the
360 Int J Adv Manuf Technol (2020) 109:345–376

Table 5 The analytical models of

the nanofluids for viscosity [116] Model The effective nanofluid viscosity ratio Application

Einstein 1 + Ƞ Ʋp At no nanoadditives interactions and Ʋp is less than 1%

Batchelor 1 + Ƞ Ʋp + (Ƞ Ʋp)2 Brownian motion and interactions of nanoadditives
Ward 1 + Ƞ Ʋp + (Ƞ Ʋp)2 + (Ƞ Ʋp)3 Ʋp is greater than 35%

effective nanofluid viscosity ratio (i.e., nanofluid viscosity/ longer cutting tool life was achieved. Setti et al. [82] has con-
base fluid viscosity) as shown in Table 5. These models vary centrated their study to control the friction behavior in the
depending on the nanoadditive volume fraction and the dy- grinding processes. It helps to evaluate the work piece surface
namics of their interactions. The nanofluid rheological behav- and abrasive particle interactions that affect the output param-
ior has been classified into four main sections [142]: eters. The nanoparticle was added into the base fluid within
various concentrations. The titanium grade 5 was used as
& Nanofluids with volume fraction less than 0.1% and their workpiece material, while the grinding forces, chip formation,
viscosity is associated with the Einstein model (without morphology, etc. were considered as outputs. It was conclud-
shear thinning); ed that application of MQL along with the nanofluid leads to
& Nanofluids with volume fraction between 0.1 till 5% (no an improvement in the quality of the workpiece. Zhang et al.
obvious shear thinning); [81] made observations while grinding of 45 steel with the
& Nanofluids with volume fraction between 5 till 10% (ob- assistance of nanoparticle enriched solutions. Various lubrica-
served shear thinning); tions strategies have been employed (i.e., flood, MQL, and dry
& Nanofluids with volume fraction greater than 10% cutting). It has been observed that the lubrication property can
(nanoadditives interpenetration). be improved through the use of high nanocutting fluid viscos-
ity. Therefore, the heat transfer performance can be enhanced
as well. On the other hand, the optimal mass concentration for
MoS2 nanoparticles into the base cutting fluid was 6 wt%. Sen
4.4 Improvements of machining quality et al. [148] performed milling experiments on Inconel-690
characteristics alloy using MQL mist cooling system. The investigations re-
sults were compared with other lubrication techniques (i.e.,
Recently, many researches have focused on the use of multi- dry, MQL with palm oil, nanosized silica at various propor-
walled carbon nanotube (MWCNT) in combination with the tions from 0.5 to 1 vol% dispersed in palm oil). The
base fluid because of its excellent impact to machining pro- nanocutting fluid-based method mixed with 1 vol% silica
cess [8]. In addition to improving the thermal conductivity, the has shown promising results. It can reduce the tool wear, sur-
nanoparticles also help to lessen the friction between the face roughness and resultant cutting force due to its cooling
workpiece and tool surfaces. The lubrication improvement and lubricating effects, which lead to a decrease on the cutting
leads in a better dimensional accuracy and superior surface zone temperature. Yildirim et al. [110] carried out turning
texture quality [143]. Other studies have been confirmed that experiments on Inconel-625 alloy under hexagonal boron ni-
the increase in the nanoparticle concentration in conjunction trite (hBN) mixed nanofluid-MQL in different volume frac-
to a smaller particle size allows improvements in the thermal tions of 0.5% and 1%. They compared findings with other
conduction of the cutting fluid [144]. The MQL as single lubrication techniques, i.e., dry and pure-MQL (without any
process and in combination with nanoparticle fluids and nanoadditives). The 0.5 vol% hBN dispersed nanofluid based
MWCNT were applied to machine a chromium-based carbon MQL method has exhibited better outputs.
alloy (AISI D2). It was noticed that only conventional MQL The effectiveness of an integrated approach that uses the
technique offers inferior results compared to the combined nanofluid-assisted MQL in the turning, milling, grinding, and
method [145]. In another promising work, Sharma et al. drilling processes was successfully demonstrated. The
[146] extended the effects of the abovementioned system in suspended nanoadditives containing diverse sizes are intro-
the turning of AISI 304 alloy. It was concluded that the com- duced in the base oil allows to boost the heat transfer coeffi-
bined methodology offered better surface finish, coefficient of cient. They enable uniformly distribution of heat into the cut-
friction, cutting force, as well as tool life due to an improve- ting zone. Besides, the prolonged tool life is also linked to the
ment of thermal conductivity. Singh et al. [147] performed MQL-based nanofluids (NFs). Owing to nanopowders behav-
research analysis while machining titanium grade 3 alloy. ing as an intermediate layer between the surfaces in contact is
The comparisons were made between dry medium, traditional possible to obtain a substantial reduction in frictional coeffi-
oils, and a specially created MQL fluid enriched with nano- cient. Hence, superior surface finish, less cutting forces and
particles. The surface texture was greatly improved, and a tool wear are obtained. The key advantages of integrating the
Int J Adv Manuf Technol (2020) 109:345–376 361

nanoadditives with MQL mechanism are summarized as fol- manufacturing, and zero post-process cleaning. The performance
lows [149]: of MQL technique can give better results when integrated
nanofluid with biodegradable oil. As the following mechanism
– A fine mist is achieved by combining the high-pressure plays a vigorous role on the nono-lubricant released in mist form:
air and nanoadditives atomized through MQL nozzle. (1) Spherical nanoscale powders have a great tendency to rotate
– The superior tribological properties (lower friction with and slip between tool workpiece surfaces. (2) A thin protection
better lubrication) is achieved by impinging the film may get develop on the surface of the workpiece and tool
nanoadditive-assisted MQL droplets on the cutting in- due to the ability of nanosized particles to form the friction pairs.
sert/chip/workpiece interfacial creating a thin-film layer. (3) The formation of a tribo-film of nanoadditives due to accu-
– The multifarious sized nanoparticles enable to increase in mulation of particles on the contacted surfaces, leading to
the overall nanoadditive concentration. This multifarious mending effect such as lost-mass compensation. (4) The uniform
sized nanoadditves work as a key role for spacer and compressive forces beared by the nanosized particles while the
penetrated closer to tool-workpiece interface. compressive stress produced as high contact pressure were re-
– The nanocutting fluid used in conjunction with the high- duced significantly [119]. Figure 11 depicts the NF behavior
pressure, on the MQL system, can spread homogeneous between the two sliding surfaces.
on the narrow tool-workpiece interface. It prevents a di- In addition, Hegab and Kishawy [150] investigated the
rect contact of tool with the workpiece surface. The operating mechanism associated with the MQL-nanofluid.
higher number of particles produce thin and a protecting Figure 12 presents a schematic of the proposed mechanism.
tribo-film on the newly machined surface. Here, the nanofluids were atomized through MQL employing
with a certain percentage of compressed air to form a biode-
The MQL-NFs helps to improve a bonding mechanism at the gradable oil assisted fine mist. This fine mist has the capabil-
tool-workpiece interface. That is why the applied NFs may im- ity to enter well into the tool/chip/workpiece interfacial
prove the tool life, surface finish and by restricting the cutting forming a tribo-film layer to limit coefficient of friction and
temperature and force. These techniques have demonstrated fa- generated cutting heat as well. Therefore, addition of NFs in
vorable performance while maintaining an environment for sus- MQL much enhanced the lubri-cooling functions to sustain
tainable machining. The conclusion from overall above discus- the uniform hardness of cutting tool for longer time. Thus, the
sion can be summarized as practicing biodegradable green oils or MQL-nanofluid entails superior performance regarding the
conventional mineral oils through MQL application are useful in tool wear behavior when matched under cutting using pure
cutting operation leading to decrease in the cutting temperature, MQL without any addition of single or hybrid nanoadditives.
tool wear, cutting forces, and surface roughness. It is pertinent to Additionally, Hegab et al. [151] provided an obvious insight
mention that a comparison of MQL with dry and flood condi- of the abrasive impacts that is generated as result of the ap-
tions was put forward to achieve the machining characteristics. plication of MQL nanofluid. At high concentration, a high
Besides, MQL technique uses a very small quantity (10,000 abundance of nanoparticles in the resultant NFs collides with
times less than flood) of lubricant rather than using few liters each other. Because, they are impeded due to the work sur-
per second in flood cooling. The MQL approach also encourgaes face asperities, thus producing a high cutting force.
a green cutting, i.e., eco-benign, environmentally friendly Consequently, the nanoadditive induces the wear process,

Fig. 11 NFs behavior when

sliding between two surfaces: a
rolling effect of spherical
nanoadditives, b a nanoprotective
film, c the mending, d the
polishing effects [119]
362 Int J Adv Manuf Technol (2020) 109:345–376

Fig. 12 The nanoadditive assisted

MQL mechanism [150]

which is boosted by incrementing the nanoadditives concre- when is used the nanotechnology. Some of them are summa-
tion as discussed previously. Subsequently, the resulting rized below:
flank wear will grow that will affect the surface quality of a
final product. It can be seen in Fig. 13 that the high concen- & The main concerns are related to a no sufficient agreement
tration of nanoadditives means more intensive additives in between the results obtained in various studies. Moreover,
NFs impinging on contact surfaces in the operation region. there is a compulsory need for investigation of properties
The direct contact of the cutting tool with the workpiece that drive the lubrication mechanisms [152].
surface is limited by the layer of nanoadditives, so the & Long-term stability of nanofluid: It is one of the most
resulting friction is reduced because the employed mist be- important demands needed as the nanoparticles are easily
come spacer in the cutting zone. Establishing the above un- aggregated because of the Van Der Waals interactions.
derstanding, it can be asserted that nanoadditives amount Numerous proposed solutions have been applied and pre-
should be attentively chosen to make balance between sented (e.g., using surfactant); however, the time period
considerations. after preparing the nanofluid is a critical factor as the
nanoparticles agglomeration can happen [153].
& The challenges of the nanofluids/nanoadditives produc-
4.5 Nanofluid application challenges tion (e.g., sedimentation, clustering, agglomeration): An
effective recommendation to face these challenges has
In spite of all favorable characteristic of nanofluids, there are been obtained through establishing a multi-disciplinary
still a few challenges that need to be addressed and resolved approach, which can lie between the thermal, mechanical,
chemical, and materials science aspects [154].
& The high cost of nanofluids [8].
& The nanofluid thermal behavior in turbulent flow cases:
There are required to investigate the convective heat trans-
fer and thermal conductivity in the situation of turbulent
flows. However, only few studies have obtained promis-
ing results for using nanofluids in the turbulent flow cases
[155, 156]. The building of a general analytical model that
express the flow mechanisms effects is highly required.

5 Miscellaneous MQL upgradations with cold

air supply

Although, the nanofluids are being extensively used for

upgrading the existing MQL approach, there are yet other tech-
niques being used in combination with the MQL process. The
literature is flooded with researches on MQL. Thus, there is
need to upgrade the existing process with other advanced tech-
Fig. 13 The effect of nanoparticle concentration in MQL-nanofluid niques. The following section lists and explains the advantages
mechanism [151] of combining some useful techniques with the MQL process.
Int J Adv Manuf Technol (2020) 109:345–376 363

Fig. 14 Cryo-MQL nozzle

arrangements [159]

5.1 Cryogenic-MQL combinational applications perfect blend between the technical and environmental benefits
with much better output parameters. In another work Park et al.
Cryogenic-MQL refers to using MQL assisted by cryogenic air. [161] compared several cooling techniques, by conducting ex-
It is believed that the combination of cryogenic air with the MQL periments with different cooling and lubrication regimes. They
leads to a much-improved outcome when compared to the ones addressed that cryogenic cooling and MQL exhibited better per-
obtained without using chilled air. In one of the earlier attempts, formance than both dry and wet cutting. However, it was report-
He et al. [157] conducted turning experiments to compare MQL ed that the exposure to liquid nitrogen leads to thermal damage to
with cryogenic assisted MQL process in terms of cutting tool the cutting insert and the hardening of the workpiece metal in
life. The cutting tool used consists of an internal cooling system machining, resulting in poor tool life and microbreakage and
for passing cryogenic air through in order to assist the cooling increasing cutting forces. Zou et al. [162] turned 3Cr2NiMo alloy
process. The data observation from experiments showed that the using a diamond cutting tool. The comparisons were done to
combining of MQL medium with cryogenic air-cooling might compare the combinational effectiveness effect of cryo-MQL
improve the tool life and surface quality. Moreover, it was also cooling. It was reported that the flank wear is reduced by more
noted that the use of compresses cryogenic air also helps to easy than 50%. In addition, a perfect finish was obtained in the sam-
break the chip. In another similar study, Chetan et al. [158] ple. Thus, it was concluded that the use of cryo-MQL is highly
performed the turning of Nimonic 90 alloy at variable speeds beneficial for the tool life and product quality when machining
under different cooling regimes. It was reported that both air- with a diamond tool. In one of the most recent studies, Shokrani
cooling and MQL offer similar results. However, the combined et al. [163] performed a detailed analysis on the effect of
use of the MQL and cryogenic cooling could lead to a substantial cryogenic-MQL combinational effect in order to detect various
advancement. responses. The evaluation shows that a higher tool life is due to
In a similar attempt, as shown in Fig. 14, Pereira et al. [159] the combinational cooling technique that is superior when is
used a unique nozzle system to supply a combined stream of compared to the flood cooling.
MQL coolant and cryogenic CO2 into the cutting zone. The
experimentation was performed on Inconel 718 alloy. The pro- 5.2 Ranque-Hilsch vortex tube (RHVT)–MQL
cess was made using fixed cutting parameters, but comparisons combinational applications
were made among several cooling regimes in order to find the
best cooling method, which provides longer tool life. It was Another source of cold air that can be developed to replace the
concluded that although the wet flood cooling offers the highest cryogenic gases is generated with a vortex tube. This device is
tool life, the combinational cooling using MQL + CO2 also could made of a completely stationary part that only requires com-
provide a tool life equivalent to 92% of the life provided by the pressed air as input. The air outlet with a reduced temperature
wet cooling. This was accompanied with the minimum use of can be used for the cooling purpose. There is a lot of scope for
coolant and much lower cooling cost. In addition, this process is improvement because it has been used only in very limited sit-
completely environment friendly. In continuation to their previ- uation. We have noticed that the literature volume available on
ous work, Pereira et al. [160] involved the use of computational the use of a vortex tube for machining purposes is almost neg-
fluid dynamics (CFD) techniques to improve the nozzle design ligible. In one of the earlier attempts, Alsayyed et al. [164] used a
that permits to achieve efficient cooling and lubrication while vortex tube during milling of brass material. The comparison
machining aerospace alloys. Some theoretical analyses were was made between3 conventional coolants in terms of cutting
compared with the CFD simulations that were corroborated with temperature and surface texture. It was shown that the vortex
experimental results. They state that this technique provides a tube allows reducing the cutting temperature due to its cooling
364 Int J Adv Manuf Technol (2020) 109:345–376

Fig. 15 Construction and working principle of a Ranque-Hilsch vortex tube [167]

effect, but is not able to reduce the roughness. The conventional failed to give good results at lower speeds due to the absence of
cooling offers a better surface texture. Lopes et al. [165] explored its lubricating effect. Gupta et al. [7], in a relatively latest and
the grinding of the AISI 4340 alloy using MQL under cold air simple work, compared the cutting temperatures in machining
with vortex tube. They observed that promising results with using different tool materials as well as coolants. The RHVT was
cutting fluid applied at 0 °C. Another study by Taha et al. used as one-coolant competitors. Hence, the cutting temperature
[166] compared the use of a vortex tube with ambient air was found the highest under dry conditions. In a recently pub-
cooling. The experiments were performed while milling of lished article, Mia et al. [167] conducted some experimental
A36 steel workpiece. It was concluded that the vortex tube comparison by combining RHVT with nitrogen gas. The com-
was only effective at higher speeds due to its cooling effect but parisons were made with dry cutting, nitrogen cutting and nitro-
gen MQL. It was concluded that the inclusion of an RHVT (refer
Fig. 15) in the system assisted to improve the machining out-
comes. It is clear that the use of the RHVT in conjunction to
machining operations can be made with minimum cost addi-
Cryogenic
OR RHVT Conventional tions; however, the results can be improved considerable.
cooled air MQL
Appendix Table 11 presented the work related that combine
the applications of MQL with cryogenic gases and RHVT.

6 Conclusions

A robust review was presented associated with the MQL and its
use along with different machining operations. This study per-
mits to reduce the gap in the existing literature and proves the
Improvment in the machining process (Tool wear, Forces, success of using advanced methods of lubrication. Figure 16 de-
Power, Surface Integrity, Tool life, Sustainability, etc. ) picts the key aspects, which enable superior performance for
different machining operations (turning, milling, grinding, and
Fig. 16 Graphical representation of the conclusion drilling). In summary, the main conclusions are drawn as follows:
Int J Adv Manuf Technol (2020) 109:345–376 365

1. MQL parameters: in numerous researches related to the improvements, yet some challenges are on the nanofluid
MQL, the comparisons were simply made with the existing technology usage, such as; long-term dispersion stability
alternatives like dry, flood or cryogenic machining. There of NFs, complexities in turbulent flow cases, higher cost
is no evident effort where MQL has been upgraded by a of nanoparticles, and challenges related to production pro-
particular process and then compared against the classical cess of nanofluids/nanoadditives.
MQL process. Since 2002, the comparison with dry and 6. For other possible MQL upgrades, it is worth to investigate
flood techniques has been well established and the results further combination with cryogens such as liquid Nitrogen.
was implemented in the most industrial applications. They may help to improve as well as the results. Moreover,
2. The use of MQL method significantly improves the ma- the use of a Ranque-Hilsch vortex tube can also reduce the
chinability characteristics such as surface quality, tool life, cutting temperatures significantly. It was noticed that a very
tool wear, cutting forces, cutting temperature. However, it limited volume of work is related to the use of vortex tube.
is obviously the need of further upgrade into the MQL 7. In the available literature, it can be said that dry machining
process. Further improvement should be related to the main is the best way with regard to sustainable and environ-
MQL parameters, i.e., fluid flow rate, compressor pressure, mental issues. Yet, considering both sustainability and
nozzle location, nozzle angle, nozzle number, etc. Such efficiency together, it can be clearly stated that traditional
variations and their relative effects may throw light on im- MQL and nanofluid-MQL methods are the best alterna-
portant results. Moreover, the correct determination of tive in machining operations.
MQL fluid type, MQL operating parameters and cutting
parameters depending on each material/cutting tool pair is
substantially important for sustainable production.
3. In light of the information collected from the available
literature, most of the previous studies stated that the 7 Future directions
MQL cooling/lubrication method made significant im-
provements in performance outputs in operations such The following recommendations can be incorporated in order
as turning, grinding, milling and drilling. However, some to upgrade and to obtain sustainable cooling/lubrication
researchers have identified the negative effects of MQL processes.
on the workpiece material and grinding wheels in the
grinding process. Therefore, studies on hybrid methods 1. Electrostatic MQL (EMQL) and ultrasonic assisted vibra-
and nanofluid employment have been intensified to make tion MQL (UAV-MQL) could be implemented in turning,
the MQL method more effective. Especially, nanofluid- milling, grinding and deep drilling processes since it is re-
MQL has contributed significantly to the machining pro- ported as the latest trend in upgradation of MQL technique.
cess compared to traditional pure-MQL. 2. Ionic liquids with biodegradable base oil (1-butyl-3-
4. There is a quite limited amount of work available for the methylimidazolium cation as additive to castor oil) assisted
MQL used for boring process. The boring or internal turn- MQL can be used to improve the lubricity efficiency dur-
ing is one of the critical processes used in the manufactur- ing the machining of ultra-hard materials/composites.
ing industry and needs more attention when cutting oper- 3. Particularly in the cutting of difficult-to-machine alloys,
ation. Thus, the use of MQL strategy within boring pro- the combination of MQL and MQCL can be employed by
cess opens new perspective of highly quality manufactur- applying addition of nanosized solid lubricants into
ing for critical components. vegetable-based cutting fluid. In these combined systems,
5. A comprehensive literature survey related to the nanofluid hybrid nanofluids can be also preferred for effective
technology has been presented and discussed. The cooling and lubrication.
nanocutting fluids have depicted favorable results regard- 4. Some studies demonstrating the benefits of hybrid nano-
ing the base liquid features, but mentioned advances can- particles have been performed recently and they reported
not be obvious in the absence of employing a sufficient that they are very beneficial to increase both the thermal
dispersion method. The improvements are primarily fo- conductivity and lubricity features of base liquid.
cused on the thermal, tribological, and rheological fea- Therefore, more research can be done on the performance
tures. There various works were established for different of biodegradable oil-based hybrid nanofluids.
empirical and analytical models to explore a correlation 5. To increase the applicability of NFs in machining opera-
between the operating parameters and their response pa- tions, more investigations are needed to improve the long-
rameters. Moreover, the nanocutting fluids have provided term dispersion stability of NFs, wettability, complexities in
favorable findings regarding the machining performance turbulent flow cases, and challenges related to production
measures (e.g., cutting forces, friction behavior, tool wear, process of nanofluids/nanoadditives and to put models of
cutting zone temperature). Despite of previous the tribological and heat propagation mechanisms of NFs.
366 Int J Adv Manuf Technol (2020) 109:345–376

6. In recent years, although many different nanoparticles have processes to reduce energy, power consumption, and pro-
been used in the MQL system, more studies are required on mote economic production.
the optimum volume fraction and size of nanoparticles and
the time during which NFs can be preserved without losing Acknowledgments The authors are grateful to the China Post-Doctoral
Science Foundation Funded Project (2019TQ0186), National Natural
performance and producing bacteria.
Science Foundation of China (no. 51922066), the Major projects of
7. In order to achieve better cooling as well as good lubrica- National Science and Technology (Grant No. 2019ZX04001031), the
tion, cryogenic cooling plus hybrid NFs-MQL may be Natural Science Outstanding Youth Fund of Shandong Province (Grant
considered as it offers promising results up to now for No. ZR2019JQ19), the National Key Research and Development
Program (Grant No. 2018YFB2002201), and the Key Laboratory of
machining of materials that have poor thermal conductiv-
High-efficiency and Clean Mechanical Manufacture at Shandong
ity and high reactivity against tool materials. University, Ministry of Education.
8. In order to indicate the relationship between green and
sustainable production, well-known models such as life Compliance with ethical standards
cycle assessment (LCA) can be applied to the above-
mentioned cooling/lubrication methods in conventional Conflict of interest The authors declare that there is no conflict of
machining operations. Moreover, various analytical interest.
models can be developed for different machining

Appendix

Table 6 MQL in turning process

Reference (s) Work/tool material Cutting parameters Cutting environment/fluid Parameters evaluated

Dhar et al. AISI 1040 steel Vc = 64,80,110,130 Dry, wet, and MQL Cutting temperature, chip reduction ratio and
[21] Uncoated carbide insert. f = 0.10, 0.13, 0.16, Soluble oil as coolant dimensional deviation.
0.20 p = 7 bar and flow rate = 60 ml/h
ae = 1.0
Sreejith [25] Aluminum 6061 alloy Vc = 400 Dry, MQL, flooded coolant Tool wear, surface roughness, and cutting
Diamond coated carbide f = 0.15 Bp-microtrend oil. force.
tool ae = 1.0 MQL applied 50 ml/h and 100 ml/h
Khan et al. AISI 9310 steel Vc = 246, 348, 483 Dry, wet, and MQL Cutting temperature, chip pattern, tool wear,
[26] Uncoated carbide TTS f = 0.10, 0.13, 0.16, Food grade vegetable oil and surface roughness.
0.18 p = 6 bar
ae = 1.0
Vasu en Inconel 600 alloy Vc = 40, 50, 60 Dry, wet, and MQL with nanoparticles Surface roughness, tool-tip interface
Reddy Coated carbide f = 0.08, 0.12, 0.16 Al2O3 nanoparticles in vegetable oil temperature, cutting force, tool wear, and
[49] ae = 0.4, 0.8, 1.2 chip formation.
Amrita et al. AISI-1040 steel Vc = 105 MQL nanoparticle Cutting force and tool flank wear.
[33] HSS and cemented f = 0.14 Nanographite powder (80 nm) size in
carbide tool ae = 1 proportion 0.1, 0.3, and 0.5%,
soluble oil used
Hadad and AISI 1040 steel Vc = 40.7 Dry, flooded, mist with nanographite Cutting temperature, tool wear and cutting
Sadeghi, HSS and cemented f = 0.14 Mist with nanographite of 0.1, 0.3, force.
[35] carbide ae = 1 0.5% weight
Sharma and AISI D2 steel Vc = 79, 96, 130 Dry and MQL machining Cutting temperature, surface finish and
Sidhu [38] Tungsten carbide insert f = 0.5, 0.10, 016 Accu lube 6000 cutting fluid microhardness.
ae = 1 P = 1 bar
Mishra et al. EN-24 steel Vc = 80, 160, 240 MQL Surface roughness.
[50] CNMG120408 f = 0.04, 0.08, 0.12 p = 5 bar
Coated carbide insert ae = 0.2, 0.3, 0.4 Flow rate = 50 ml/h
Chetan et al. Nimonic-90 and Vc = 60, 120 Dry and MQL Nose, flank and rake wear, cutting force.
[46] Ti-6Al-4V PVD f = 0.15, 0.25 Sunflower oil in water (10:1), nozzle
coated carbide insert ae = 0.5 spray at 3 bar
Cetin et al. AISI 304 l steel Vc = 100 Vegetable-based cutting liquid MQL Surface roughness,
[51] Titanium nitride inserts f = 0.1 and commercial cutting fluid Tool wear and turning force.
ae = 1
Mishra et al. Ti6Al4V Uncoated Vc = 90 MQL and nMQL
[52] carbide f = 0.1 p = 4–7 bar
Int J Adv Manuf Technol (2020) 109:345–376 367

Table 6 (continued)

Reference (s) Work/tool material Cutting parameters Cutting environment/fluid Parameters evaluated

ae = 1 flow rate = 100–250 ml/h Main cutting forces, contact length and contact
area, coefficient friction, tool wear, chip
morphology.
Maheshwera Inconel 718 alloy Vc = 60, 80, 100 Dry and MQL Surface roughness, S/N ratio for the result
et al. [53] Carbide cutting. f = 0.1, 0.5, 0.3 Tungsten disulfide dispersed 0.5% wt obtained by Taguchi method.
ae = 0.05, 0.75, 0.1 in emulsion oil
Das et al. AISI 4340 steel Vc = 80, 100, 120, Water soluble coolant and Al2O3-based Cutting forces, chip thickness, and tool wear.
[54] Uncoated cermet insert 140 nanofluid-MQL
f = 0.05, 0,1, 0,15, Flow rate = 150 ml/
0.2 p = 7 bar
ae = 0.1, 0.2, 0.3,
0.4
Ozbek and AISI D2 steel Vc = 60, 90, 120 Dry and MQL Cutting temperature, surface roughness,
Saruhan PVD and CVD coated f = 0.09 mm/rev Flow rate = 150 ml/h vibration, tool wear, and tool life.
[23] carbide insert ae = 1 p = 6 bar

*Units of cutting speed, Vc = m/min; feed rate, f = mm/rev; depth of cut, ae = mm

Table 7 MQL in milling processes

Reference/year Work/tool material Cutting parameters Environment/cutting fluid Parameters evaluated

Liao and Lin NAK-80 mold steel Vc = 300, 400, 500 Dry and MQL Tool wear and surface roughness
[57] Indexable carbide insert f = 0.10, 0.15, 020 Biodegradable ester
Axial depth = 0.3 Flow rate = 10 ml/h
Radial depth = 5 P = 0.45 mPa
Thamizhmanii Inconel 718 Vc = 10, 20, 30 MQL vegetable sunflower oil, flow Surface roughness, tool wear.
and Super hard cobalt tool. f = 0.15 rate = 12.5, 25, 37.5 ml/h
Hasan [58] ae = 0.40
Thepsonthi ASSAB DF3 hardened steel Vc = 125, 150, 175 Pulsed jet MQL, dry, and flooded Flank wear, surface texture, cutting
et al. [59] Ti-Al-N coated carbide ball f = 0.01, 0.02, 0.03 Pulsing rate = 400 pulse/min, zone temperature
end-mill inserts ae = 0.2 mm p = 20 mPa
Flow rate rate = 2 ml/min.
Li and Chou SKD 61 steels Vc = 200, 225, 250 Air =25 and 40 l/min p = 0.5Mpa Tool flank wear, surface roughness.
[60] Two-flute flat end mills f = 0.01, 0.015 flow rate = 1.88, 3.75, and 7.5 ml/h
ae = 0.03 MQL, dry, and near micro-milling.
Silva et al. [61] Compact graphite cast irons Vc = 200 and 300 Dry and MQL with Tool life, surface quality, and electric
TiN- and TiAlN-coated f = 0.1 and 0.2 Vascomil MMS FA 2 fluid current consumption
cemented carbide cutting Flow rate = 50 ml/h
tools Pressure = 6 bar
Taylor et al. Tool steel with 53 HRC Vc = 250 MQL and dry Tool life
[62] Coated cemented carbide f = 0.05 Plant oil based cutting fluid
ball-nose tool Radial depth = 0.75
Axial depth = 10
Zhang et al. Inconel 718 Vc = 55 Dry and MQCL Tool wear and cutting temperature.
[63] Cemented carbide. f = 0.1 Bescut −173 cutting oil.
Axial depth = 0.5
Radial depth = 1
Wang et al. Inconel 182, Vc = 160, Dry and MQL Tool wear and microstructures.
[66] PVD-coated tool inserts. f = 0.2, Accu-Lube type MQL system,
ae = 1 vegetable oil.
Priarone et al. Titanium aluminides Vc = 25, 50, 100 Dry, wet and MQL. Tool wear and surface roughness
[67] Ti-48Al-2Cr-2Nb f = 0.08 Aerosol of LB2000 vegetable-based
Tungsten carbide inserts. ae = 0.3 oil, p = 5.5 bar
Jang et al. [69] SM45C structural steel. Vc = 1200, 1600, Dry and MQL machining Various applications for optimization
Two-blade flat-end mill. 2300, 3000 rpm Vegetable cutting oil, flow rate = 0, and specific cutting energy.
f = 0.02, 0.03, 0.04 2, 10 ml/min
ae = 1.0, 1.5, 2.0

*Units of cutting speed, Vc = m/min; feed rate, f = mm/rev; depth of cut, ae = mm

368 Int J Adv Manuf Technol (2020) 109:345–376

Table 8 MQL in grinding process

Reference/year Work/tool material Cutting parameters Environment/cutting fluid Parameters evaluated

Da Silva et al. [71] ABNT 4340 steel VS = 30 m/s Conventional, MQL, and dry Surface integrity.
Aluminum oxide a = 0.1 grinding
grinding wheels LB-1000 lubricant
Tawakoli et al. [72] 100Cr6 vitrified bond VC = 1800 Dry, fluid, air jet, Mql supply Grinding force and surface quality.
wheels ae = 0.03 Syntilo XPS Castrol in a 5%
Vft = 3000 mm/min concentration.
Flow rate = 100 ml/h
Liao et al. [73] Ti-6A14V alloy VC = 1800 MQL using a mixture of water and Grinding forces and coefficient of
Diamond wheel WS = 4.2 m/s Besol 37 cutting oil friction “lotus effect” of
grinder ae = 0.01, 0.015, and 0.02 nanoparticles, surface finish.
Sadeghi et al. [74] AISI- 4140 steel VC = 1800 Dry, wet and MQL. Grinding force and surface quality of
Aluminum oxide WS = 10, 20, 30, 40 Vegetable oil, synthetic oil, Behran ground parts.
grinding wheels. ae = 0.005, 0.010, 0.015 cutting oil.
Qu et al. [75] Carbon Flow rate = 40, 60, 80, Conventional wet, dry, MQL, Surface roughness/topography,
fiber-reinforced 100 ml/h and p = 3, 5, NMQL. Carbon grinding force, sub-surface
ceramic matrix 7, 9 bar nanoparticle-based nanofluid and damages, and grinding debris.
composites Vs = 26 m/s pure fluid were applied in MQL
Diamond grinding Vw = 3 m/min grinding.
wheel ae = 0.03
Kalita et al. [76] Cast iron and EN24 Vc = 1800 MQL using nanolubricants, pure Friction coefficient of grinding,
steel ae = 0.02 base oils, base oils containing specific energy and grinding ratio.
vitreous bonded WS = 0.06 and 0.1 m/s MoS2 base oils containing MoS2
aluminum oxide Paraffin oil Soybean oil.
(Al2O3) grinding Flow rate = 2.5 ml/min
wheel
Balan et al. [79] Inconel −751 VC = 2826 MQL grinding Grinding force, surface roughness
Resin bond diamond Ws = 0.9 Cimtech D14 MQL oil, and temperature.
wheel ae = 0.03 flow rate = 60, 80, 100 ml/h
p = 2, 4, 6 bar
Zhang et al. [81] Steel 45 Vc = 1800 Dry, flood lubrication, MQl and Coefficient of friction, normal,
K-P36 numerical Vw = 3000 m/min nanoparticle jet. tangential and axial force, Ra,
control ae = 0.01 Base oil Liquid paraffin, Palm oil specific energy.
Precise grinder Rapeseed oil Soybean oil (2 wt.%
flow rate = 50 ml/h),
nozzle distance =12 mm
Setti et al. [82] Titanium alloy VC = 1020 Dry, wet and MQL with soluble oil Coefficient of friction, ground
Ti-Ti-6Al-4V ae = 0.005 Al2O3 and CuO nanofluids and surface and chip characteristics
Silicon carbide water as a base fluid. and chip formation.
Oliveira et al. [85] AISI 4340 steel Vw = 0.58 m/s Flood coolant, MQL, MQL Wheel cleaning, surface roughness,
Cubic boron nitrite ae = 0.012, 0.025, 0.037 accompanied by wheel cleaning geometric error, microhardness,
acoustic emission.
Bianchi AISI 4340 steel Vc = 1800 Conventional technique MQL plus Surface finish, geometrical error,
et al. [86, 87] Aluminum oxide Vf = 0.5 mm/min WCJ method and conventional wheel wear at diameter, power,
grinding wheel Vw = 0.58 m/s MQL method (non-cleaning microhardness.
ae = 0.012, 0.025, 0.037 wheel cleaning way)
Bianchi et al. [88] AISI 4340 steel Vc = 1800 MQL Surface roughness, roundness
Cubic boron nitrite Vf = 0.5 mm/min deviation, diametrical grinding
Ws = 0.58 m/s wheel wear, power.
Lopes et al. [89] Alumina Vc = 1800 Conventional cooling, only-MQL, Grinding wheel wear, power,
Diamond wheel Vf = 0.5 mm/min mm/min MQL plus air jet with angles from workpiece quality.
nw = 204 rpm 0 degrees to 90 degrees
Javaroni et al. [90] Alumina Vc = 1800 m/s, Conventional, MQL Surface finish, dimensional error,
Diamond wheel Vf = 0.75, 1, 1.25 mm/min G-ratio, and output acoustic
ae = 0.1 emission

*Units of cutting speed, Vc = m/min; feed rate, f = mm/rev; depth of cut, ae = mm

Int J Adv Manuf Technol (2020) 109:345–376 369

Table 9 MQL in drilling process

Reference/year Work/tool material Cutting parameters Environment/cutting fluid Parameters evaluated

Bhowmick et al. [92] AM60 magnesium alloy VC = 1000, 1500, 2000, Dry, H2O-MQL, FA-MQL Torque, thrust force, Surface
HSS twist drill 2500 rpm flooded texture and chip morphology.
f = 0.10, 0.15, 0.20 and 0.25
Rahim and Sasahara [93] Titanium (Grade 5) VC = 60, 80, 100 Dry and MQL Surface roughness, tool life, thrust
Coated carbide drill (TiAlN) f = 0.1 and 0.2 Synthetic ester and palm oil. force, torque and work piece
d = 14 mm temperature, micro-hardness.
Rahim and Sasahara [94] Inconel 718 Vc = 30, 40, 50 MQL Microhardness, surface roughness,
Coated carbide (TiAlN) f = 0.05 and 0.1. Synthetic ester and palm oil. surface defects and sub-surface
t = 20 mm Flow rate = 103 ml/h deformation.
d = 14 mm
Kuram et al. [95] AISI 304 stainless steel Spindle speed = 320, 420, MQL with vegetable-based fluids Thrust measurement and surface
HSS-E tool 520 rpm roughness.
f = 0.10, 0.12, 0.14
t = 15, 18, 21 mm
Biermann et al. [96] Aluminum cast alloy EN VC = 140, 200 MQL Mechanical load, heat load and
AC-46000 f = 0.1, 0.3 P = 14 bar simulation of deep hole
solid carbide tool
Chatha et al. [97] Aluminum 6063 VC = 30, 53.7 Dry, flooded, mist cooling, Forces, torque, Ra, coefficient of
HSS drills bits f = 60 mm/min nanoparticle-enriched mist friction, drill wear.
t = 20 cooling
P = 70 psi

*Units of cutting speed, Vc = m/min; feed rate, f = mm/rev; depth of cut, ae = mm

Table 10 Literature summary of the thermal conductivity enhancements for various nanofluids (water-based)

References Nanoadditive type Nanoadditive Volume fraction % The percentage of thermal

diameter (nm) conductivity improvement %

Assael et al. [124] MWCNT 100 0.6 38

Assael et al. [124] MWCNT 130 0.6 28
Lee et al. [118] CuO 36 3.4 12
Lee et al. [118] CuO 23.6 3.5 12
Lee et al. [118] CuO 23 9.7 34
Lee et al. [118] CuO 23 4.5 17
Lee et al. [118] Al2O3 33 4.3 15
Lee et al. [118] Al2O3 38.4 4 10
Murshed et al. [125] TiO2 15 5 30
Murshed et al. [125] Cu 100 7.5 78
Murshed et al. [125] TiO2 10 5 33
Murshed et al. [125] TiO2 10 0.5 8
Masuda et al. [126] Al2O3 13 4.3 30
Masuda et al. [126] Al2O3 13 4.3 30
Masuda et al. [126] TiO2 27 4.3 10.8
Masuda et al. [126] TiO2 27 3.25 8.4
Liu et al. [127] Cu 100 0.1 24
Xuan et al. [128] Cu 100 2.5 22
Li and Peterson [129] Al2O3 36 10 22
Patel et al. [130] Au 10 0.026 21
Patel et al. [130] Ag 60 0.001 17
Patel et al. [130] Al2O3 36 2 15
Xie et al. [131] Al2O3 68 5 21
Xie et al. [131] Al2O3 60.4 5 20
Xie et al. [131] Sic 26 4.2 16
Xie et al. [131] Al2O3 60.4 1.8 7
Xie et al. [131] MWCNT 15 1 7
Yu et al. [132] CuO 28.6 4 14
Yu et al. [132] Al2O3 38.4 4 9
Jana et al. [133] Al2O3 28 3 12
Kang et al. [134] Ag 15 0.39 11
Wen and Ding [135] Al2O3 42 1.59 10
Chon et al. [136] Al2O3 11 1 9
Chon et al. [136] Al2O3 47 4 8
370 Int J Adv Manuf Technol (2020) 109:345–376

Table 11 Combined applications of MQL with cryogenic gases and RHVT

Reference/year Process/work/tool material Cutting parameters Environment/cutting fluid Parameters evaluated

He et al. [157] Turning, 304 stainless steel, Vc = 43, 75, 108, Dry Tool life and chip
coated carbide tool 160, 217 m/min Cryo-air (0.4 MPa, − 20 °C) morphology
f = 0.12 mm/rev Cryo-MQL(0.4 MPa, − 20°, 30 ml/h)
ap = 0.4 mm
Chetan et al. [158] Turning Vc = 40, 60, Dry Flank wear and
Nimonic90, 80 m/min MQL surface finish
CNMG120408-THM-F f = 0.1 mm/rev Cryogenic
uncoated carbide ap = 1 mm
Pereira et al. [159] Milling Vc = 120 m/min Dry, Tool life
Inconel 718 ap = 0.2 mm Wet,
ARAF–Ball nose finishing CO2 cryogenic,
end mill MQL (Vegetal oil, Flow rate = 100 ml/h),
CO2 + MQL(100 ml/h) + CO2 (14 bar, −80 °C
Pereira et al. [160] Milling,Inconel 718 Vc = 120 m/min Cryo-MQL cooling Flank wear, tool life
ARAF–ball nose finishing ap = 0.2 mm
end mill
Pereira et al. [160] Milling Vc = 47, 76, 100, Dry, MQL, cryogenic, MQL+ cryogenic Cutting forces, Tool
Ti-6Al-4V 120 mm/rev wear, Chip
R245-12T3M-KM(H13A) f = 0.15 mm/rev morphology
Uncoated carbide insertap = 2 mm
Zou et al. [162] Turning Vc = 40 m/min CMQL (Cryo MQL) Tool wear
3Cr2NiMo f = 0.01 mm/rev
Diamond tool ap = 1 mm
Shokrani et al. [163] End milling Vc = 60, 90, 120, Dry Tool wear, Surface
Ti-6Al-4V 150, 180 m/min MQL roughness
Solid coated carbide f = 0.03 mm/tooth Cryogenic
ap = 1 mm MQL + cryogenic
Taha et al. [166] Turning Vc = 160 m/min Dry, RHVT Temperature
A36 steel f = 0.10, 0.18, Tool wear
Tungaloy Tnmg 160,408 tmt 0.28 mm/rev
9125 coated carbide ae = 1–4 mm
Mia at al. [167] Turning Vc = 160, AC, NGC, NGMQL, RHVT-NGMQ Surface roughness
AluminumT6 alloy 320 m/min Tool wear
CNMG120404 WIDIA f = 0.05,
0.15 mm/rev
ae = 2 mm
Alsayyed et al. [168] Milling, brass Vc = 850 rpm Dry, conventional coolant, RHVT Temperature
ae = 0.5 mm Surface texture
Gupta et al. [169] Turning Vc = 355 rpm Water, dry, soluble oils, RHVT Cutting temperature
HSS, uncoated carbide

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Affiliations

Gurraj Singh 1 & Munish Kumar Gupta 2 & Hussein Hegab 3 & Aqib Mashood Khan 4 & Qinghua Song 2,5 &
Zhanqiang Liu 2,5 & Mozammel Mia 6 & Muhammed Jamil 4 & Vishal S. Sharma 7 & Murat Sarikaya 8 & Catalin Iulian Pruncu 6

1 5
Industrial and Production Engineering Department, Dr. B.R. National Demonstration Center for Experimental Mechanical
Ambedkar NIT Jalandhar, Punjab, India Engineering Education, Shandong University, Jinan, People’s
2 Republic of China
Key Laboratory of High Efficiency and Clean Mechanical
6
Manufacture, Ministry of Education, School of Mechanical Mechanical Engineering, Imperial College London, London, UK
Engineering, Shandong University, Jinan, 7
School of Mechanical, Industrial & Aeronautical Engineering,
People’s Republic of China
University of the Witwatersrand, Johannesburg, South Africa
3
Mechanical Design and Production Engineering Department, Cairo 8
Department of Mechanical Engineering, Sinop University,
University, Giza 12163, Egypt
Sinop, Turkey
4
College of Mechanical and Electrical Engineering, Nanjing
University of Aeronautics and Astronautics, Nanjing 210016, China