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Article Enhancing Machining Efficiency and Sustainability of Ti-6Al-4V Through Minimum Quantity Lubrication With Ester-Based Oils(Taylor & Francis Ltd, 2025) Namlu, Ramazan Hakki; Kavut, Kuebra; Tom, Hanife GulenTi-6Al-4 V is known as difficult-to-cut due to its low thermal conductivity and high chemical reactivity. While cutting fluids aid lubrication and reduce friction, Conventional Cutting Fluids (CCF) have high consumption, limited efficiency gains and negative environmental and health effects. Therefore, there is an ongoing search for more sustainable alternatives to CCF that do not adversely affect machining performance. Minimum Quantity Lubrication (MQL), which delivers compressed air - oil aerosol, has emerged as a promising solution by drastically reducing fluid use and associated risks. Selecting the right MQL fluid is key to optimising machining performance. This study evaluates MQL fluids based on polyol and polymeric esters for Ti-6Al-4 V machining and compares their performance with CCF. Cutting forces, surface roughness and topography are examined. Results show that MQL reduces cutting forces up to 21.7% and surface roughness up to 57.6% compared to CCF, with more uniform surface topography. Among MQL oils, polymeric esters perform better than polyol esters, with a reduction in cutting force up to 14.6% and surface roughness up to 47.7%. High viscosity indexed polymeric esters showed the best overall performance due to their thermal stability. Moreover, according to the sustainability assessment analysis polymeric esters were identified as the most sustainable option.Article Citation - WoS: 38Citation - Scopus: 39Enhancing Machining Efficiency of Ti-6al Through Multi-Axial Ultrasonic Vibration-Assisted Machining and Hybrid Nanofluid Minimum Quantity Lubrication(Elsevier Sci Ltd, 2024) Namlu, Ramazan Hakki; Lotfi, Bahram; Kilic, S. EnginTi-6Al-4V offers a balance of good strength with lightweight properties. Yet, Ti-6Al-4V poses machining challenges, including low thermal conductivity, chemical adhesion to cutting tools, and chip removal difficulties. To improve machining efficiency, Ultrasonic Vibration-Assisted Machining (UVAM) has emerged as a promising approach. UVAM has demonstrated reduced tool wear, cutting forces, and improved surface quality compared to Conventional Machining (CM). Additionally, Minimum Quantity Lubrication (MQL) methods offer sustainable coolant alternatives, with recent research focusing on Nanofluid-MQL (NMQL) and Hybrid Nanofluid-MQL (HNMQL) for enhanced performance. Although there exists a body of literature showcasing the promising effects of UVAM and MQL methods individually, comprehensive investigations into the synergistic effects of these methodologies remain limited. This study addresses these critical research gaps by conducting a systematic examination of combined application of multi-axial UVAM and HNMQL. Specifically, it delves into the comparison of different vibration directions within UVAM, evaluates the effectiveness of UVAM when combined with cutting fluids incorporating Al2O3 and CuO nanoparticles in NMQLs and HNMQLs, and contrasts these novel approaches with conventional machining methods. The study unfolds in three distinct stages. The first stage examines the ultrasonic cutting mechanism and its combined application with the MQL technique. In the second stage, the study investigates the physical properties of the cutting fluids, including contact angle and surface tension. The final stage encompasses slot milling operations, where an array of parameters such as cutting forces, surface roughness, surface topography, surface texture, and the occurrence of burr formations are rigorously analyzed. The results demonstrate that the combination of multi-axial UVAM with HNMQL yields substantial advantages over traditional machining methods. Notably, it leads to a remarkable reduction in cutting forces (up to 37.6 %) and surface roughness (up to 37.4 %). Additionally, this combination engenders the production of highly homogeneous and uniform surface textures, characterized by minimal surface defects and a significantly diminished occurrence of burr formations. These findings underscore the potential of multi-axial UVAM combined with HNMQL as a promising approach in enhancing the machining of Ti-6Al-4V, thus offering a pathway to enhance the efficiency and precision of aerospace component manufacturing processes.Conference Object Citation - WoS: 19Citation - Scopus: 23An Experimental Study on Surface Quality of Al6061-T6 in Ultrasonic Vibration-Assisted Milling with Minimum Quantity Lubrication(Elsevier Science BV, 2022) Namlu, Ramazan Hakki; Yilmaz, Okan Deniz; Lotfisadigh, Bahram; Kilic, S. EnginAl6061-T6 is frequently used in the automotive and aerospace industries, where milling is an essential process, due to its high strength-to-weight ratio. In order to achieve improved surface quality in milling, Ultrasonic Vibration-Assisted Milling (UVAM) has been introduced recently. Besides, Minimum Quantity Lubrication (MQL) is another advanced method to enhance the surface properties of the cutting by improving the coolant performance. However, the effects of simultaneous implementation of UVAM and MQL methods has not yet been studied sufficiently. This paper investigates the effects of applying UVAM in tandem with MQL in cutting of Al6061-T6. The results showed that surface quality enhanced with this combination. (c) 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)Article Citation - WoS: 7Citation - Scopus: 10Combined Use of Ultrasonic-Assisted Drilling and Minimum Quantity Lubrication for Drilling of Niti Shape Memory Alloy(Taylor & Francis inc, 2023) Namlu, Ramazan Hakki; Lotfi, Bahram; Kilic, S. Engin; Yilmaz, Okan Deniz; Akar, SametThe drilling of shape-memory alloys based on nickel-titanium (Nitinol) is challenging due to their unique properties, such as high strength, high hardness and strong work hardening, which results in excessive tool wear and damage to the material. In this study, an attempt has been made to characterize the drillability of Nitinol by investigating the process/cooling interaction. Four different combinations of process/cooling have been studied as conventional drilling with flood cooling (CD-Wet) and with minimum quantity lubrication (CD-MQL), ultrasonic-assisted drilling with flood cooling (UAD-Wet) and with MQL (UAD-MQL). The drill bit wear, drilling forces, chip morphology and drilled hole quality are used as the performance measures. The results show that UAD conditions result in lower feed forces than CD conditions, with a 31.2% reduction in wet and a 15.3% reduction in MQL on average. The lowest feed forces are observed in UAD-Wet conditions due to better coolant penetration in the cutting zone. The UAD-Wet yielded the lowest tool wear, while CD-MQL exhibited the most severe. UAD demonstrated a & SIM;50% lower tool wear in the wet condition than CD and a 38.7% in the MQL condition. UAD is shown to outperform the CD process in terms of drilled-hole accuracy.Article Citation - WoS: 13Citation - Scopus: 16An Experimental Study on Ultrasonic-Assisted Drilling of Inconel 718 Under Different Cooling/Lubrication Conditions(Springer London Ltd, 2024) Erturun, Omer Faruk; Tekaut, Hasan; Cicek, Adem; Ucak, Necati; Namlu, Ramazan Hakki; Lotfi, Bahram; Kilic, S. EnginUltrasonic-assisted drilling (UAD) is one of the efficient and innovative methods to improve the drillability of difficult-to-cut materials. In the present study, the UAD of Inconel 718 was investigated under different cooling and/or lubrication conditions. The drilling tests were carried out at a constant cutting speed (15 m/min) and a feed (0.045 mm/rev) using uncoated and TiAlN-coated solid carbide drills under dry, conventional cutting fluid (CCF), and minimum quantity lubrication (MQL) conditions. The applicability of UAD to drilling Inconel 718 was evaluated in terms of thrust force, surface roughness, roundness error, burr formation, subsurface microstructure and microhardness, tool wear, and chip morphology. The test results showed that, when compared to conventional drilling (CD), UAD reduced the thrust force and improved the hole quality, tool life, and surface integrity under all conditions. Good surface finish, lower roundness error, and minimum burr heights were achieved under CCF conditions. MQL drilling provided lower thrust forces, better tool performance, and good subsurface quality characteristics. In addition, the simultaneous application of CCF-UAD and MQD-UAD showed significantly better performance, especially when using the coated tool.
