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<p>Currently, ultra-precision machine tools generally employ minimum quantity lubrication (MQL) or air cooling as the primary lubrication methods. Insufficient lubrication and cooling in the cutting zone often lead to increased cutting forces and accelerated tool wear, resulting in higher surface roughness and reduced machining accuracy. In this study, using Mobil ISOPAR_H as the base oil, ultra-precision turning experiments were carried out under four lubrication conditions: MQL, MoS<sub>2</sub>-NMQL, BN-NMQL, and Al<sub>2</sub>O<sub>3</sub>-NMQL. A comparative analysis was conducted on the effects of different lubrication conditions on cutting force fluctuations, tool wear, and machining quality. Thereafter, combined with SEM, XPS, and other microscopic and surface analysis techniques, the role mechanisms of MoS<sub>2</sub> nanoparticles in oil film enhancement and friction and wear reduction were revealed. The experimental results show that, compared with MQL, MoS<sub>2</sub>-NMQL reduces the average main cutting force and thrust force by 10.8% and 22.1%, respectively. The analysis results of the worn surface morphology and chemical composition show that MoS<sub>2</sub> nanoparticles have good filling and repairing effects, reducing the surface roughness of the workpiece by 12.5%. In addition, the average wear of the rake and flank faces also decreased by 27.3% and 12.5%, respectively. EDS analysis indicates that the S and Mo atoms in MoS<sub>2</sub> react with the metal surface, promoting the formation of a continuous and dense adsorption layer at the tool–chip interface, effectively inhibiting the originally dominant adhesive and abrasive wear. Ultimately, the roundness error of the spherical shell decreased by 30.7%, and the profile error was reduced by 28.4%.</p>

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Effects of MoS2 Nanofluid Minimum Quantity Lubrication on Cutting Force, Tool Wear, and Machining Quality in Ultra-Precision Turning of Thin-Walled Spherical Shells

  • 期刊论文

  • 发表日期：

    2026年3月7日

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  • Xiangzhou Ding,
  • Xuefei Wang,
  • Jiasheng Li,
  • Dong Wang,
  • Quanwei Yang,
  • Xiuru Li,
  • Minglong Guo,
  • Zhaocheng Wei

摘要

Currently, ultra-precision machine tools generally employ minimum quantity lubrication (MQL) or air cooling as the primary lubrication methods. Insufficient lubrication and cooling in the cutting zone often lead to increased cutting forces and accelerated tool wear, resulting in higher surface roughness and reduced machining accuracy. In this study, using Mobil ISOPAR_H as the base oil, ultra-precision turning experiments were carried out under four lubrication conditions: MQL, MoS2-NMQL, BN-NMQL, and Al2O3-NMQL. A comparative analysis was conducted on the effects of different lubrication conditions on cutting force fluctuations, tool wear, and machining quality. Thereafter, combined with SEM, XPS, and other microscopic and surface analysis techniques, the role mechanisms of MoS2 nanoparticles in oil film enhancement and friction and wear reduction were revealed. The experimental results show that, compared with MQL, MoS2-NMQL reduces the average main cutting force and thrust force by 10.8% and 22.1%, respectively. The analysis results of the worn surface morphology and chemical composition show that MoS2 nanoparticles have good filling and repairing effects, reducing the surface roughness of the workpiece by 12.5%. In addition, the average wear of the rake and flank faces also decreased by 27.3% and 12.5%, respectively. EDS analysis indicates that the S and Mo atoms in MoS2 react with the metal surface, promoting the formation of a continuous and dense adsorption layer at the tool–chip interface, effectively inhibiting the originally dominant adhesive and abrasive wear. Ultimately, the roundness error of the spherical shell decreased by 30.7%, and the profile error was reduced by 28.4%.