AP26100207 «Development of technology for producing environmentally friendly nanomodified cutting fluids based on vegetable oils»
SDG #12
Project Leader
Stepanova Olga, NJSC «Shakarim University», Head of the Department, PhD, professor
Relevance
The global market for metalworking fluids/cutting fluids (MWFs) remains dominated by synthetic and petroleum-based products (≈ two-thirds), whose use entails significant environmental risks: contamination of surface and groundwater, air, and soil, with downstream impacts on food security and public health. Against this backdrop, the development of a technology for environmentally friendly, nanomodified, vegetable-oil-based cutting fluids-with an eye to application in MQL systems (minimum quantity lubrication)- is highly relevant. The biodegradability of vegetable bases reduces toxic environmental loads, while enhanced thermal conductivity and improved tribological properties achieved via nanoparticles (Al2O3, TiO2, MWCNT, Cu, Ag) enable more effective cooling and lubrication of the cutting zone at minimal flow rates. A comprehensive study of a broad set of vegetable oils (coconut, soybean, castor, sunflower, rapeseed, palm, jojoba) with selection of optimal nanocomponents will provide a scientifically and practically meaningful alternative to mineral-oil MWFs, aimed at shrinking the environmental footprint and resource intensity of metalworking.
Goal
Modification of cutting fluids based on vegetable oils with nanoparticles in order to obtain environmentally friendly nanofluids for use in mechanical processing of metals.
Expected Result
1. A method for producing nanomodified cutting and cooling lubricants (CCL) based on vegetable oils has been developed.
2. The obtained composition has been combined with MQL (Minimum Quantity Lubrication) technology, ensuring the environmental safety of CCLs used in metal machining.
3. Data on the required physical and chemical properties of CCLs for MQL systems have been obtained.
4. The features of using vegetable oils in MQL technology have been studied.
5. Based on the obtained data, a methodology for synthesizing nanomodified CCLs has been developed and optimized.
6. The optimal composition of the CCL and the effective concentration of nanoparticles have been determined, and a technology for nanomodification of lubricating and cooling fluids has been created.
7. An effective method for stabilizing nanofluids has been established.
8. The thermal conductivity and viscosity of various nanomodified CCL compositions have been studied.
9. The temperature dependence and stability of the obtained nanofluids have been determined.
10. Experimental studies of metal cutting processes in the environment of nanomodified CCLs have been carried out.
11. Various technological regimes for supplying nanomodified CCLs have been tested.
12. The surface properties of metals treated with different CCL compositions have been investigated.
13. The obtained experimental data have been analyzed, and the main issues affecting the performance of the developed CCLs have been identified.
14. Considering the identified issues, the composition and production technology of nanomodified CCLs have been improved.
15. Repeated experiments with improved nanofluid compositions have been conducted.
16. A comparative analysis of surface quality and performance for different compositions of CCLs has been performed.
17. The heat transfer process during metal cutting in a nanomodified CCL environment has been modeled based on the experimental data.
18. Recommendations for the use of nanomodified CCLs in material machining have been developed.
19. Based on the project results, at least three (3) scientific articles and/or reviews will be published in peer-reviewed journals indexed in Web of Science (Science Citation Index Expanded) and/or Scopus, included in Q1–Q3 quartiles or having a CiteScore percentile of at least 60.
20. At least two (2) additional articles or reviews will be published in peer-reviewed foreign or domestic journals recommended by KOKNVO, one of which must belong to the multidisciplinary category.
21. For domestic journals from KOKNVO List 1, which are not multidisciplinary, journals indexed in two or more categories from Lists 1 and 2 will be accepted.
22. The project results will be realized through publications in the following international journals:
- Wear (Scopus CiteScore 88%, Web of Science Q1), Elsevier;
- Results in Engineering (Scopus CiteScore 82%, Web of Science Q1), Elsevier;
- Journal of Manufacturing Processes (Scopus CiteScore 89%, Web of Science Q1), Elsevier;
- or other peer-reviewed journals indexed in Science Citation Index Expanded and/or Scopus (CiteScore ≥ 60%).
23. For domestic publications, results will be published in:
- Reports of the National Academy of Sciences of the Republic of Kazakhstan (KOKNVO List 2, Physical and Chemical Sciences);
- Bulletin of the National Nuclear Center of the Republic of Kazakhstan (KOKNVO List 2, Physical Sciences);
- Bulletin of D. Serikbayev East Kazakhstan Technical University (KOKNVO List 2, interdisciplinary journal indexed in Engineering, ICT, Architecture, and Construction).
24. The training of one PhD student is planned, with a research topic directly related to the project theme.
25. Research results will also be presented in mass media and at domestic and international scientific conferences for testing and dissemination.
26. The application field of the project is mechanical engineering.
27. The developed nanomodified CCLs will have environmentally safe properties, which are essential for environmental protection and sustainable development goals.
28. The practical significance of the project lies in the development of a technology for producing eco-friendly cutting and cooling lubricants intended to replace toxic and non-degradable mineral-based fluids used in industry.
Achieved Result
- Data on the required properties of metalworking fluids (MWFs) for MQL systems were obtained. The specific features of vegetable oils when used in this technology were investigated. These findings were taken into account in the synthesis of nanomodified MWFs.
The key characteristics of using vegetable oils as a base fluid were identified, including their influence on thermal conductivity, viscosity, and heat removal performance. Based on the analysis of experimental data, property benchmarks were refined for the subsequent synthesis of nanofluids containing Al₂O₃, TiO₂, MWCNT, Cu, and Ag nanoparticles.
For base vegetable oils, a kinematic viscosity range of 20–50 mm²/s at 40 °C was adopted. For Al₂O₃ and TiO₂ nanoparticles, the effective working concentration range was determined to be approximately 0.5–1.0 wt.%, at which a thermal conductivity enhancement of about 15–40% is achieved without excessive viscosity growth. For MWCNTs, small dosages of 0.1–0.3 wt.% are considered appropriate; for Cu nanoparticles, 0.2–0.5 wt.%; and for Ag nanoparticles, around 0.6 wt.% in a vegetable oil base with surfactants.
These results were accepted as initial data for the synthesis of nanomodified MWFs and for selecting optimal formulations suitable for MQL applications.
- An optimal composition of the metalworking fluid (MWF) was obtained, the effective nanoparticle concentration was determined, and the nanomodification technology for MWFs was developed. An effective method for stabilizing nanofluids was also identified.
For nanoparticles within the concentration range of 0.5–1.0 wt.%, a series of experiments was conducted. Based on the results, the optimal region was identified, and the following findings were obtained:
– Effective concentrations.
For Al₂O₃ and TiO₂ nanoparticles, a working range of 0.5–1.0 wt.% was established. At 0.5 wt.% Al₂O₃, the best balance between tribological performance and viscosity was observed. A further increase in concentration to ≥1 wt.% leads to higher viscosity and an increased risk of adhesive wear.
For copper (Cu) nanoparticles, effective performance was demonstrated in the range of 0.2–0.5 wt.%, where reductions in cutting forces and surface roughness parameter Ra were recorded.
For silver (Ag) nanoparticles dispersed in vegetable oil with the addition of the surfactant Tween-80, the optimal concentration was found to be about 0.6 wt.%. At this concentration, a significant reduction in surface roughness Ra was achieved compared to both dry machining and the corresponding base fluid without silver nanoparticles.
– Nanomodification technology of MWFs.
A two-stage dispersion scheme was developed: mechanical stirring → ultrasonication for 30–60 minutes → subsequent surfactant stabilization.
It was shown that CTAB, SDBS, and Tween-80 provide long-term dispersion stability and enhanced heat transfer. Increasing the ultrasonication time to approximately 60 minutes improves stability without noticeable nanoparticle degradation.
– For oil-based systems, stabilization is recommended by combining surfactants (CTAB/SDBS/Tween-80, and oleic acid if necessary) with ultrasonic treatment and dispersion control.
- The thermal conductivity and viscosity of various compositions of nanomodified metalworking fluids (MWFs) were investigated. The temperature dependence of these properties, as well as the stability of the obtained nanofluids, was determined.
The following results were obtained:
– Thermal conductivity (λ).
An increase in λ of vegetable base oils was recorded after the addition of nanoparticles in low concentrations: approximately +15–40%, depending on the particle type and volume fraction (φ ≤ 1%). The most pronounced effects were observed for hybrid compositions and carbon-based nanoparticles (MWCNTs).
– Viscosity (μ).
It was shown that μ increases with increasing nanoparticle concentration but decreases with rising temperature. For vegetable oil-based Al₂O₃ nanofluids, the increase in μ with higher φ and the decrease in μ upon heating were experimentally confirmed. At the same time, concentration ranges were selected to ensure proper delivery in MQL systems without nozzle clogging.
– Temperature dependences λ(T) and μ(T).
It was experimentally established that upon heating (within the operating temperature range of MQL), λ(T) increases while μ(T) decreases, which improves heat removal and pumpability. For MWCNT-based and hybrid systems, the effect on λ(T) is more pronounced due to the high intrinsic thermal conductivity of the nanoparticles and thermodiffusion effects.
– Stability studies.
Nanofluids based on vegetable oils, within the same nanoparticle concentration range, demonstrated significantly higher stability compared to water-based nanofluids, which is attributed to the higher viscosity of vegetable oils.
Scientific Team
Степанова Ольга Александровна
NJSC "Shakarim University", Head of the Department "Technical Physics and Thermal Power Engineering", Candidate of Technical Sciences / Professor
Касымов Аскар Багдатович
NJSC "Shakarim University", Member of the Board – Vice-Rector for Strategy and Social Development, PhD
Бектемисов Ануар Алмасбекович
NJSC "Shakarim University", PhD Doctoral Student of the Educational Program "Technical Physics"
Ермоленко Михаил Вячеславович
NJSC "Shakarim University", Senior Lecturer of the Department "Technical Physics and Thermal Power Engineering", Candidate of Technical Sciences, Associate Professor (Docent)
Умыржан Темірлан Нұрланұлы
NJSC "Shakarim University", PhD Doctoral Student of the Educational Program "Technical Physics"
Акишов Жандос Қайрбекұлы
NJSC "Shakarim University", PhD Doctoral Student of the Educational Program "Technical Physics"
Жамбаева Маржан Қанатқызы
NJSC "Shakarim University", PhD Doctoral Student of the Educational Program "Technical Physics"
Астемесова Каламкас Сериковна
Head of the Department of General Physics, A. Burkutbayev Institute of Power Engineering and Mechanical Engineering
Мануленко Антон Иванович
NJSC "Shakarim University", Engineer of the Department "Technical Physics and Thermal Power Engineering"
Байсакалова Гульшат Ескалиевна
Accountant
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Contact
Scientific Department:
+7 (7222) 31-31-75
science@shakarim.kz