Investigation of the machinability performance of aa 6082 aluminum alloys with minimum quantity lubrication (MQL) and nano-mql applications

In this thesis study, the machinability performance of AA 6082 aluminum alloy in turning operations was experimentally investigated by machining it under different cutting parameters and lubrication conditions. Within the scope of the study, Minimum Quantity Lubrication (MQL) and titanium carbide (TiC) nanoparticle-reinforced MQL (Nano-MQL) applications were evaluated in comparison with dry machining; fundamental machinability criteria such as cutting force, surface roughness, tool wear, and chip morphology were considered. Experimental studies were conducted on a conventional lathe machine, with a new cutting tool (TiC-coated carbide insert) used in each operation. Cutting parameters included cutting speed (65 and 100 m/min), feed rate (0.2 and 0.4 mm/rev), and chip depth (0.2 and 0.4 mm). The effects of these parameters on machinability performance were systematically analyzed under both dry and lubricated conditions. Experimental data were evaluated graphically; S/N ratio analysis was performed for cutting forces and surface roughness, along with a statistical approach known as analysis of variance (ANOVA). The results of the study showed that the Nano-MQL environment provided the most successful results in all performance criteria. In particular, it was found that the cutting fluid containing 1% TiC nanoparticles significantly reduced tool wear, improved surface roughness, and resulted in lower cutting force values. MQL conditions also provided better machinability performance compared to dry machining. SEM analyses revealed that crater wear was largely prevented under nano-additive lubrication conditions, while chip morphology became more regular and controlled. It was concluded that the nano-MQL system constitutes an important alternative for AA 6082 aluminum alloy in terms of sustainable and high-efficiency production processes. In this context, this study provides an important contribution to both academic research and industrial applications