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<p>Traditional flood cutting fluids are limited by high consumption and serious environmental pollution. Minimum quantity lubrication (MQL) greatly cuts fluid consumption yet still faces prominent bottlenecks in high-speed and difficult-to-cut material machining, such as air barrier resistance, poor wetting performance and unstable lubricating film. Wetting enhancement technology via multi-field synergy has become a key solution to address these deficiencies. This paper systematically reviews the latest advances in relevant techniques. It elaborates typical approaches including pneumatic, electrostatic and ultrasonic atomization, nozzle optimization, intelligent control, nanofluids, textured tools and ultrasonic vibration assistance. The underlying physical essence is analyzed, and three core mechanisms are concluded: atomization improvement, flow field regulation and interface modification. Combined with turning, milling and grinding characteristics, the targeted optimal wetting strategies for different processing methods are clarified. Finally, future development directions are prospected, including adaptive regulation, composite field synergy, eco-friendly lubricants, intelligent equipment research and development, as well as multi-scale theoretical research. Representative experimental data verify the effectiveness: electrostatic atomization MQL for GH4169 milling reduces cutting force by 15.2%-15.9% and surface roughness by 30.9%-54.2%; ultrasonic assisted nanofluid MQL for Ti-6Al-7Nb machining lowers surface roughness by 57% and strengthens interfacial lubrication and surface quality. The wetting enhancement technology improves green cutting theories, supports high-efficiency precision machining of difficult-to-cut materials, and facilitates the green and intelligent upgrading of modern manufacturing.</p>

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Wetting enhanced technologies for minimum quantity lubrication machining: synergistic strategies, mechanisms and challenges

  • 期刊论文

  • 发表日期：

    2026年6月17日

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  • Xiaoming Wang,
  • Zhiguo Sang,
  • Jixin Liu,
  • Xiaotian Zhang,
  • Dewei Liu,
  • Wenhao Xu,
  • Wei Wang,
  • Teng Gao,
  • Lan Dong,
  • Xuesong Chang,
  • Xing Zhao,
  • Yanbin Zhang,
  • Min Yang,
  • Xin Cui,
  • Benkai Li,
  • Yusuf Suleiman Dambatta,
  • Feng Pang,
  • Changhe Li

摘要

Traditional flood cutting fluids are limited by high consumption and serious environmental pollution. Minimum quantity lubrication (MQL) greatly cuts fluid consumption yet still faces prominent bottlenecks in high-speed and difficult-to-cut material machining, such as air barrier resistance, poor wetting performance and unstable lubricating film. Wetting enhancement technology via multi-field synergy has become a key solution to address these deficiencies. This paper systematically reviews the latest advances in relevant techniques. It elaborates typical approaches including pneumatic, electrostatic and ultrasonic atomization, nozzle optimization, intelligent control, nanofluids, textured tools and ultrasonic vibration assistance. The underlying physical essence is analyzed, and three core mechanisms are concluded: atomization improvement, flow field regulation and interface modification. Combined with turning, milling and grinding characteristics, the targeted optimal wetting strategies for different processing methods are clarified. Finally, future development directions are prospected, including adaptive regulation, composite field synergy, eco-friendly lubricants, intelligent equipment research and development, as well as multi-scale theoretical research. Representative experimental data verify the effectiveness: electrostatic atomization MQL for GH4169 milling reduces cutting force by 15.2%-15.9% and surface roughness by 30.9%-54.2%; ultrasonic assisted nanofluid MQL for Ti-6Al-7Nb machining lowers surface roughness by 57% and strengthens interfacial lubrication and surface quality. The wetting enhancement technology improves green cutting theories, supports high-efficiency precision machining of difficult-to-cut materials, and facilitates the green and intelligent upgrading of modern manufacturing.