Evaluation of new nano-cutting fluids for the processing of carbon fiber-reinforced composite materials

Abstract

Carbon fiber-reinforced composites (CFRP), known for its impressive specific strength and modulus, finds extensive applications in defense, aerospace, automotive, and various other industries. Nevertheless, the widespread application of dry cutting in machining Carbon Fiber Reinforced Polymer (CFRP) presents significant challenges, including dust pollution, fiber layer delamination , and uneven surface quality. These issues make the machining of CFRP a formidable task. In the present investigation, a novel nanohybrid cutting fluid was successfully prepared by adding molybdenum disulfide (MoS 2 )/silicon carbide (SiC) nanoparticles to a base-cutting fluid synthesize from ethanol, polyethylene glycol , and sodium dodecyl sulfate . Moreover, employing minimal lubrication techniques , the nano-cutting fluid was applied to the milling process of CFRP. The feasibility of applying the cutting fluid to CFRP machining was demonstrated through short beam shear tests. Horizontal comparative milling tests were executed on CFRP, varying operational parameters and cooling-lubrication scenarios. The cooling-lubrication mechanisms of the nanofluid were analyzed, providing further validation of the effectiveness of the cutting fluid in CFRP machining. The results suggest that the nanofluid has a negligible impact on the interlaminar shear strength of CFRP, with only a 3.85% reduction. In comparison to other cooling-lubrication conditions, milling CFRP with the novel nanofluid resulted in a reduction of milling forces by 4.78%–24.84%, a decrease in milling temperatures by 15.38%–69.37%, a lowering of surface roughness by 10.78%–35.93%, and a reduction in tool tip wear by 6.25%–53.81%. Observable phenomena such as fiber pull-out and fracture were significantly reduced. • A nanohybrid cutting fluid suitable for CFRP machining is prepared, which is free of precipitation, agglomeration and delamination . • The effect of nano-cutting fluid on the mechanical properties of CFRP was proved to be negligible by interlayer shear strength tests. • The experimental results of cutting force, cutting temperature, surface quality and tool wear in milling CFRP were analyzed through comparative tests, which proved that the prepared nano-cutting fluid has good cooling and lubricating properties. • This study focuses on the development of a nano-cutting fluid tailored for CFRP. The findings contribute valuable insights into the selection of cutting fluids for CFRP machining.