26 Investigate the Possibility of Using Carbon Onion Nanolubrication with DLC Cutting Tool to Reduce the Machining Power Consumption Ahmed. A. D. Sarhan 1,* , M. E. Ooi 2 , M. Sayuti 3 , M. Hamdi 4 Abstract— Due to rapid consumption of world's fossil fuel resources and impracticality of large-scale application and production of renewable energy, the significance of energy efficiency improvement of current available energy modes has been widely realized by both industry and academia. In the CNC machining field, the key solution for this issue is by increasing the effectiveness of the existing lubrication systems as it could reduce the power required to overcome the friction component in machining process. For more improvement, introducing the nanolubrication could produce much less power consumption as the rolling action of billions units of nanoparticle in the tool chip interface could reduce the cutting forces significantly. In this research work, the possibility of using carbon onion nanolubrication with DLC cutting tool is investigated to reduce the machining power consumption. Carbon onion nanolubrication has been successfully developed with high tribology performance and mixed with ordinary mineral oil. The proper sonification method is used to provide a way to mix and suspend the particles thoroughly and efficiently. Furthermore, Diamond-like carbon (DLC) cutting tool is used and expected to play significant role in reducing friction and cutting forces and increasing abrasion resistance. The results showed significant reduction of the cutting force and the working power compared with the other conditions of using carbon black and normal lubrication systems. Keywords— carbon onion nanolubrication, machining power consumption, DLC cutting tool I. Introduction In a developing country, economic growth is associated by the technology improvement particularly from the manufacturing industries. In machining processes, the improvement of saving money and sustainability performance can be done by reducing energy and power consumption. Ahmed. A. D. Sarhan (Author) University of Malaya Malaysia ah_sarhan@um.edu.my M./ E. Ooi University of Malaya Malaysia mingerh.ooi@gmail.com M. Sayuti University of Malaya Malaysia mdsayuti@um.edu.my M. Hamdi University of Malaya Malaysia hamdi@um.edu.my The cost of power used over a ten-year period is about 100 times higher than the initial purchase cost of these machine tools [1]. According to US Energy Information Administration, the fabrication of metal products consumed 47 billion kWh in 2008, which equivalent to 5% of the total industrial electricity consumption [2]. Moreover, the cost of power, materials, and waste have an impact on economic effectiveness [3]. Production companies can save up to 15% of their energy and power consumption just as easily by lubricating the machining areas with better lubricants. Turning to better lubricants pays off and it immediately lowers both energy use and direct expenses. It is fast, easy and requires minimal investment. Companies that recognize this make the switch with wonderful results [4]. Lubricants are meant to reduce the friction in the tool chip interface during machining. But not all lubricants are alike. High-quality and fully synthetic variants, for instance, reduce the friction better than normal mineral oils. As soon as the friction in machining has reduced, less energy is converted to friction heat. Beside that the amount of existing cutting force during machining will be reduced as well. Cutting force is very significant in order to achieve high accuracy and productivity and it could provide the basis information for process planning as well as to minimize the production cost and time [5, 6]. This lowers the operating temperature and the vibration levels, takes less energy to drive the machine and produces a greater output. The amount of energy that production companies can save using high-quality lubricants turns out to be between 5 and 15%. Sometimes, however, this is much more, depending among other things on the type of machine and how heavily cut it is used [7]. Making the upgrade to better lubricants is very essential for less energy in machining. High-quality lubricants are more expensive to buy, but much cheaper in use. Considering the current high energy costs and energy taxes, the use of quality lubrication usually pays for itself within very short time even if you look only at the lower energy bill. Moreover, the lubricant is used up to 5 times less frequently. The effect can be measured objectively by determining the difference in the energy use of the machine in operation before and after the upgrade with a clamp meter or the ampere-meter on the installation. This way, companies lower more than just their energy bills. They also save on pollute the environment much less with used lubricants. An important ISO 14001 target. For more develop advanced machining processes for less power consumption and pollution using less lubrication, it is clear that a multi-pronged approach must be used, including innovation in technology [8]. In this paper, authors will explore the development of carbon onion nanolubrication to Proc. of the Intl. Conf. on Advances In Mechanical And Automation Engineering – MAE 2014. Copyright © Institute of Research Engineers and Doctors. All rights reserved. ISBN: 978-1-63248-022-4 doi: 10.15224/ 978-1-63248-022-4-45 brought to you by CORE View metadata, citation and similar papers at core.ac.uk provided by UM Digital Repository