Wear suppression and interface properties of diamond tool in micro-milling of TC4 alloy under graphene nanofluid MQL environment

The sustainable micro-milling process of TC4 alloy has garnered significant attention in aerospace engineering. However, the poor machinability of TC4 alloy results in particularly severe tool wear. Tool wear directly affects the machining quality of the parts, and traditional cutting fluids of suppressing tool wear indirectly increase production costs and pollute the environment. Therefore, to suppress the negative effects caused by tool wear, this paper proposes the application of water-based graphene nanofluid in the micro-milling of TC4 alloy in diamond tools. Firstly, micro-milling experiments and molecular dynamics simulations were conducted in different environments, including dry and water-based graphene nanofluid environments. Finally, tool surface wear morphology, milling forces, surface elements and structural phase changes were compared in detail. The results show that tool wear, including adhesive wear, abrasive wear, and edge chipping, was suppressed by graphene nanofluids compared to dry conditions, thereby increasing tool life. The graphene nanofluid improved the contact state between the tool and workpiece interface, reducing the milling forces. In addition, molecular dynamics indicates that the catalytic effect of the transition elements in the workpiece on the diamond tool was also weakened, and the carbon atoms of graphene were used as a sacrificial source to balance the catalytic effect. Graphitization and diffuse wear of the diamond were suppressed. More importantly, the water-based graphene nanofluid not only improves the wear resistance of the tool, but the LCA results show its potential for sustainability. Consequently, it holds promise for advancing the sustainable processing of challenging materials.