Nano-Enhanced Cactus Oil as an MQL Cutting Fluid: Physicochemical, Rheological, Tribological, and Machinability Insights into Machining H13 Steel
The widespread use of mineral cutting fluids in metalworking poses challenges due to their poor wettability, toxicity, and non-biodegradability. This study explores cactus oil-based nanofluids as sustainable alternatives for metal cutting applications. Samples of cactus oil are prepared in plain for...
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MDPI AG
2025-06-01
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| author | Nada K. ElBadawy Mohamed G. A. Nassef Ibrahem Maher Belal G. Nassef Mohamed A. Daha Florian Pape Galal A. Nassef |
| author_facet | Nada K. ElBadawy Mohamed G. A. Nassef Ibrahem Maher Belal G. Nassef Mohamed A. Daha Florian Pape Galal A. Nassef |
| author_sort | Nada K. ElBadawy |
| collection | DOAJ |
| description | The widespread use of mineral cutting fluids in metalworking poses challenges due to their poor wettability, toxicity, and non-biodegradability. This study explores cactus oil-based nanofluids as sustainable alternatives for metal cutting applications. Samples of cactus oil are prepared in plain form and with 0.025 wt.%, 0.05 wt.%, and 0.1 wt.% activated carbon nanoparticles (ACNPs) from recycled plastic waste. Plain cactus oil exhibited a 34% improvement in wettability over commercial soluble oil, further enhanced by 60% with 0.05 wt.% ACNPs. Cactus oil displayed consistent Newtonian behavior with a high viscosity index (283), outperforming mineral-based cutting fluid in thermal stability. The addition of ACNPs enhanced the dynamic viscosity by 108–130% across the temperature range of 40–100 °C. The presence of nano-additives reduced the friction coefficient in the boundary lubrication zone by a maximum reduction of 32% for CO2 compared to plain cactus oil. The physical and rheological results translated directly to the observed improvements in surface finish and tool wear during machining operations on H13 steel. Cactus oil with 0.05 wt.% ACNP outperformed conventional fluids, reducing surface roughness by 35% and flank wear by 57% compared to dry. This work establishes cactus oil-based nanofluids as a sustainable alternative, combining recycled waste-derived additives and non-edible feedstock for greener manufacturing. |
| format | Article |
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| issn | 2075-4442 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
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| series | Lubricants |
| spelling | doaj-art-db3732f0d29d499faad9b11f2f8c8a622025-06-25T14:06:48ZengMDPI AGLubricants2075-44422025-06-0113626710.3390/lubricants13060267Nano-Enhanced Cactus Oil as an MQL Cutting Fluid: Physicochemical, Rheological, Tribological, and Machinability Insights into Machining H13 SteelNada K. ElBadawy0Mohamed G. A. Nassef1Ibrahem Maher2Belal G. Nassef3Mohamed A. Daha4Florian Pape5Galal A. Nassef6Production Engineering Department, Faculty of Engineering, Alexandria University, Alexandria 21544, EgyptProduction Engineering Department, Faculty of Engineering, Alexandria University, Alexandria 21544, EgyptIndustrial and Manufacturing Engineering Department, Egypt-Japan University of Science and Technology, New Borg El Arab City 21934, EgyptProduction Engineering Department, Faculty of Engineering, Alexandria University, Alexandria 21544, EgyptProduction Engineering Department, Faculty of Engineering, Alexandria University, Alexandria 21544, EgyptInstitute of Machine Design and Tribology, Leibniz University of Hanover, 30167 Hannover, GermanyProduction Engineering Department, Faculty of Engineering, Alexandria University, Alexandria 21544, EgyptThe widespread use of mineral cutting fluids in metalworking poses challenges due to their poor wettability, toxicity, and non-biodegradability. This study explores cactus oil-based nanofluids as sustainable alternatives for metal cutting applications. Samples of cactus oil are prepared in plain form and with 0.025 wt.%, 0.05 wt.%, and 0.1 wt.% activated carbon nanoparticles (ACNPs) from recycled plastic waste. Plain cactus oil exhibited a 34% improvement in wettability over commercial soluble oil, further enhanced by 60% with 0.05 wt.% ACNPs. Cactus oil displayed consistent Newtonian behavior with a high viscosity index (283), outperforming mineral-based cutting fluid in thermal stability. The addition of ACNPs enhanced the dynamic viscosity by 108–130% across the temperature range of 40–100 °C. The presence of nano-additives reduced the friction coefficient in the boundary lubrication zone by a maximum reduction of 32% for CO2 compared to plain cactus oil. The physical and rheological results translated directly to the observed improvements in surface finish and tool wear during machining operations on H13 steel. Cactus oil with 0.05 wt.% ACNP outperformed conventional fluids, reducing surface roughness by 35% and flank wear by 57% compared to dry. This work establishes cactus oil-based nanofluids as a sustainable alternative, combining recycled waste-derived additives and non-edible feedstock for greener manufacturing.https://www.mdpi.com/2075-4442/13/6/267cactus oilminimum-quantity lubricationdynamic viscosityrheological propertiesactivated carbon nanoparticles |
| spellingShingle | Nada K. ElBadawy Mohamed G. A. Nassef Ibrahem Maher Belal G. Nassef Mohamed A. Daha Florian Pape Galal A. Nassef Nano-Enhanced Cactus Oil as an MQL Cutting Fluid: Physicochemical, Rheological, Tribological, and Machinability Insights into Machining H13 Steel Lubricants cactus oil minimum-quantity lubrication dynamic viscosity rheological properties activated carbon nanoparticles |
| title | Nano-Enhanced Cactus Oil as an MQL Cutting Fluid: Physicochemical, Rheological, Tribological, and Machinability Insights into Machining H13 Steel |
| title_full | Nano-Enhanced Cactus Oil as an MQL Cutting Fluid: Physicochemical, Rheological, Tribological, and Machinability Insights into Machining H13 Steel |
| title_fullStr | Nano-Enhanced Cactus Oil as an MQL Cutting Fluid: Physicochemical, Rheological, Tribological, and Machinability Insights into Machining H13 Steel |
| title_full_unstemmed | Nano-Enhanced Cactus Oil as an MQL Cutting Fluid: Physicochemical, Rheological, Tribological, and Machinability Insights into Machining H13 Steel |
| title_short | Nano-Enhanced Cactus Oil as an MQL Cutting Fluid: Physicochemical, Rheological, Tribological, and Machinability Insights into Machining H13 Steel |
| title_sort | nano enhanced cactus oil as an mql cutting fluid physicochemical rheological tribological and machinability insights into machining h13 steel |
| topic | cactus oil minimum-quantity lubrication dynamic viscosity rheological properties activated carbon nanoparticles |
| url | https://www.mdpi.com/2075-4442/13/6/267 |
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