Hybrid composite stacks are multi-material laminates which find extensive applications in industries such as aerospace, automobile, and electronics. Most hybrid composites consist of multi-layer fiber composites, and metal sheets stacked together. These composite stacks have excellent physical and mechanical properties, including high strength, high hardness, high stiffness, excellent fatigue resistance, and low thermal expansion. Composite stacks are fabricated to near net shape; additional machining operations are often required for several applications, primarily in the aerospace industry. The most frequent machining operation is high-speed cold saw cutting of these hybrid stacks within specified tolerances. During the cutting process, the cutting fluids play a significant role by reducing the cutting temperature and cutting forces, thereby increasing the surface quality finish of the hybrid composite stack. However, most of the cutting fluids pose environmental and health risks. Recently, researchers have been exploring the possibilities of using MQL to overcome the adverse effects of traditional cutting fluids. This research investigates MQL based cutting of hybrid composite stacks using different types of nanoparticle-enhanced vegetable oils. Specifically, the nanoparticles of choice that have found extensive popularity within the booming nano industry: Al2O3, Al(s), Ni(s), and Carbon Nanotubes (SWCNTs). For this study, CFRP/Al and CFRP/Ti composite stacks are used as the substrates. The effects of critical process parameters on the quality, surface roughness, and interface delamination of the composite materials are studied. The process parameters under consideration include the type of vegetable oils utilized, namely, jojoba and castor oil, the nanoparticle-enhancement effects, and the construction of the hybrid composite stack. From the results of this study, it is found that the chemistry between the MQL of choice and the dispersion of the nanoparticles is of critical importance. The results of this study are expected to open new possibilities for eco-friendly and cost-effective methods for cold saw cutting advanced engineering materials.

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