Experimental Investigations Into Ionic Liquid-Based Nanofluids for Machining Difficult-to-Cut Materials

In any machining operation, cutting fluid is required to reduce the friction and heat generated between the tool-work interfaces. Reducing the cutting fluid level and their sustainability is a significant challenge associated with machining processes. In this study, the influence of Al₂O₃ nanoparticles on the Ionic Liquid (IL)-based cutting fluid is investigated. For performing it, six varying ILs (ammonium-based and immidazolium) were mixed with Al₂O₃ nanoparticles, and their lubricating behavior (viscosity, wettability, and thermal) were measured. Viscosity studies were conducted at temperatures ranging from 303–393 K, while thermal and wettability studies were conducted at room temperature. The experimental results of the study show that nanoparticles improve the thermophysical and lubrication properties. Jatropha Oil (JO) + Tetrabutylammonium bromide IL + Al₂O₃ shows the best results among the samples prepared. It shows an increase in viscosity by 17.87%, an increase in thermal conductivity by 30.5%, and a decrease in the contact angle by 32.8%, making it suitable for machining operations. Machining experimentation shows that the developed cutting fluids provide better performance in terms of reduction in cutting forces, surface roughness, coefficient of friction, and increase in shear angle compared to dry machining.