Energy-based cost integrated modelling and sustainability assessment of Al-GnP hybrid nanofluid assisted turning of AISI52100 steel

The need of a cost-effective production system is indispensable, especially in the current competitive manufacturing market. To the same extent, special attention should be focused on the sustainable and clean machining processes. Several studies have focused on the machining of hard-to-cut materials using sustainable and clean cutting technologies. However, there is a need to establish a detailed and reliable cost-energy model for sustainable machining processes. In this research, empirical models have been developed for cost and energy consumption to define the system boundaries under different cooling conditions. Mono and hybrid nanofluids have been synthesized and their performance is evaluated by analyzing viscosity, thermal conductivity, and coefficient of friction. Moreover, a holistic sustainability assessment has been performed for the measured results. The surface roughness, power and energy consumption, tool life and cost per part are determined and the results are compared with those obtained in classical MQL process. It should be noted that the study findings offer guidelines which can be easily implemented in any metal processing industry to enhance the process’s performance measures. Furthermore, this work is the first of its kind that proposes hybrid Energy-Cost models and their experimental validations.