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The purpose of this study is to reveal the friction reduction performance and mechanism of granular flow lubrication during the milling of difficult-to-machining materials and provide a high-performance lubrication method for the precision cutting of nickel-based alloys.

The milling tests for Inconel 718 superalloy under dry cutting, flood lubrication and granular flow lubrication were carried out, and the milling force and machined surface quality were used to evaluate their friction reduction effect. Furthermore, based on the energy dispersive spectrometer (EDS) spectrums and the topographical features of machined surface, the lubrication mechanism of different granular mediums was explored during granular flow lubrication.

Compared with flood lubrication, the granular flow lubrication had a significant force reduction effect, and the maximum milling force was reduced by about 30%. At the same time, the granular flow lubrication was more conducive to reducing the tool trace size, repressing surface damage and thus achieving better surface quality. The soft particles had better friction reduction performance than the hard particles with the same particle size, and the friction reduction performance of nanoscale hard particles was superior to that of microscale hard particles. The friction reduction mechanism of MoS₂ and WS₂ soft particles is the mending effect and adsorption film effect, whereas that of SiO₂ and Al₂O₃ hard particles is mainly manifested as the rolling and polishing effect.

Granular flow lubrication was applied in the precision milling of Inconel 718 superalloy, and a comparative study was conducted on the friction reduction performance of soft particles (MoS₂, WS₂) and hard particles (SiO₂, Al₂O₃). Based on the EDS spectrums and topographical features of machined surface, the friction reduction mechanism of soft and hard particles was explored.

This study aims to improve the lubrication performance of molybdenum disulfide powders at textured surface of cemented carbide materials, a squeeze motion of vibration assistance method was introduced and investigated.

Surface texture was fabricated on YT15 cemented carbide samples using a laser marking machine. After that, a tribological experiment was carried out on a self-built friction testing machine under different amplitude and frequency of squeeze motion conditions. Moreover, a simulation model was also established to verify the principle of squeeze motion on the lubrication performance improving of MoS₂ particles at textured interfaces.

Analysis results indicated that surface texture on test sample can increase the storage ability of solid lubrication particles, and the lubrication film at the contact interface is more easily formed due to the reciprocating action. Squeeze motion can improve the storage ability of it due to an intermittent contact, which provides an opportunity for MoS₂ particles infiltration, and then a more uniform distribution and load-bearing properties of force chain are also established and formed simultaneously. Thus, a better tribological performance at the contact interface is obtained.

The main contribution of this work is to provide a reference for the molybdenum disulfide powder lubrication with textured surface of cemented carbide materials.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0166/