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Studying the lubricity of new eco-friendly cutting oil formulation in metal

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DOI: 10.1108/ILT-11-2017-0330

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 Industrial Lubrication and Tribology
Studying the lubricity of new eco-friendly cutting oil formulation in metal working fluid
M.R. Noor El-Din, Marwa R. Mishrif, Satish V. Kailas, Suvin P.S., Jagadeesh K. Mannekote,
Article information:
To cite this document:
M.R. Noor El-Din, Marwa R. Mishrif, Satish V. Kailas, Suvin P.S., Jagadeesh K. Mannekote, (2018) "Studying the lubricity of
new eco-friendly cutting oil formulation in metal working fluid", Industrial Lubrication and Tribology, https://doi.org/10.1108/
ILT-11-2017-0330
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 Studying the lubricity of new eco-friendly
cutting oil formulation in metal working fluid
M.R. Noor El-Din
Egyptian Petroleum Research Institute, Cairo, Egypt
Marwa R. Mishrif
Egyptian Petroleum Research Institute (EPRI), Nasr city, Egypt
Satish V. Kailas
Department of Mechanical Engineering, Indian Institute of Science (IISc), Bangalore, India
Suvin P.S.
Center for Product Design and Manufacturing, Indian Institute of Science, India, and
Jagadeesh K. Mannekote
Center for Incubation, Innovation, Research and Consultancy (CIRC), Jyothy Institute of Technology Campus, Bengaluru, India

Abstract
Downloaded by Indian Institute of Science At 07:59 11 October 2018 (PT)

Purpose – This paper aims to formulate a new metal working fluid (MWF) composition including some eco-friendly emulsifiers, corrosion inhibitor,
biocide, and non- edible vegetable oil (castor oil) as the base oil. To achieve this aim, five MWFs with different hydrophilic–lipophilic balance (HLB)
value as 10, 9.5, 9, 8.5 and 8 were prepared to identify the optimum HLB value that gives a highly stable oil-in-water emulsion. The performance of
castor oil based MWF was evaluated using tool chip tribometer and drill dynamometer. The surface morphology of steel disc and friction pin was
performed using scanning electron microscope (SEM) and 3D profilometer. The results revealed that the use of the prepared cutting fluid (E1) caused
the cutting force to decrease from 500 N for dry high-speed steel sample to 280N, while the same value for a commercial cutting fluid (COM) was
recorded as 340 N at drilling speed and cutting feed force as 1120 rpm and 4 mm/min., respectively.
Design/methodology/approach – A castor oil-based metalworking fluid was prepared using nonionic surfactants. The composition of the
metalworking fluid was further optimized by adding performance-enhancing additives. The performance of castor oil based MWF was analyzed
using Tool chip tribometer and Drill dynamometer. The surface morphology of steel ball and a disc was done using 3D profilometer and SEM.
Findings – Studies revealed that castor oil-based MWF having Monoethanolamine (MEA) as corrosion inhibitor was found to be highly stable. The
drilling dynamometer and tool chip tribometer studies showed that castor oil-based MWF performance was comparable to that of commercial MWF.
Research limitations/implications – This study aims to explore the performance of the castor oil based metalworking fluid (MWF) using tool chip
tribometer and drill dynamometer.
Practical implications – The conventional MWFs are petroleum derives and are unsustainable. Use of non-edible plant-based oils for preparing the
MWF will not only be conserved environment but also add value addition to agricultural crops.
Social implications – The social Implications is aiming to decrease the environmental impact that results from the using of mineral cutting fluids.
Originality/value – The originality of this work is to replace the mineral oil and synthetic oil based cutting fluids with more eco-friendly alternatives
one. In addition, the investigation will focus on developing functional additives required for cutting fluids which are environmentally benign.
Keywords Metalworking fluids, Castor oil, Cutting oils, Emulsifier
Paper type Research paper

1. Introduction Furthermore, metal working fluids (MWFs) are used to reduce

Metalworking fluids (MWF) are widely used as lubricants and
coolants in a variety of industries. MWFs keep the work zone at
a stable temperature, to lubricate chip-tool interface and to
flush away chips thus reduces adverse effects of heat generated
during machining and improves surface finish of work piece
and increases the tool life (Kumar and Ramamoorthy, 2007).
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the negative effects of the heat and friction on both tool and
workpiece (Lopez de Lacalle et al., 2006). Due to their
advantages, the consumption of MWFs is increasing in
machining industry. It is reported that European Union alone
consumes approximately 320,000 tons per year of MWFs of
which, at least two-thirds need to be disposed. (Abdalla et al.,
2007). Despite their widespread use, they pose significant
health and environmental hazards throughout their life cycle.
This project was supported financially by Science and Technology
Development Fund (STDF), Egypt, Grant No. 12276.

Industrial Lubrication and Tribology Received 19 June 2017

© Emerald Publishing Limited [ISSN 0036-8792] Revised 6 November 2017
[DOI 10.1108/ILT-11-2017-0330] Accepted 12 December 2017
 Metal working fluid Industrial Lubrication and Tribology
M.R. Noor El-Din et al.

Moreover, it is reported that about 80 per cent of all
occupational diseases of operators were due to skin contact
with cutting fluids (Bennett, 1983). Estimation says that in
USA alone about 700,000 to one million workers that are
exposed to MWFs (Shashidhara and Jayaram, 2010) are
infected by skin diseases. Generally, MWFs are prepared by
emulsifying oil in water using suitable surfactants. The
Properties of emulsions are extremely sensitive to the type of
surfactants and their concentration and nature of oil. The
additives used in the composition of MWFs have a variety of
functions such as lubrication, stability of emulsion, corrosion
prevention, pH regulation and improved wetting (John et al.,
2004). Several types of MWFs are available commercially,
which include neat cutting oil, water-soluble cutting fluids,
synthetic and semi synthetic cutting fluids (Korde et al., 1993).
Conventional MWFs have mineral oil as their base oil along
with different additives for the enhancement of its performance
(John et al., 2004; Zeman et al., 1995). Mineral oil has poor
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2. Materials and methods
2.1 Materials
2.1.1 Oil base
A sample of commercial grade of castor oil phase was supplied by
Tanta Company for Oils and Soaps, Egypt. The physicochemical
properties of the used castor oil are shown in Table I. Fresh tap
water is the aqueous phase used for the preparation of MWFs.
2.1.2 Emulsifier system
Two technical grades of nonionic surfactants, namely,
polyoxyethylene (20) sorbitantristearate denoted as (T) (HLB =
10.5) and sorbitansesquioleate denoted as (S) (HLB = 3.7), were
used as emulsifiers (Sigma–Aldrich Co., Germany). This mixed
surfactant is denoted as (TS). Mono-, di- and tri-ethanoamine
are three types of corrosion inhibitors, which are denoted as M, D
and E, respectively, used in this study. Cinnamon oil and oleic
acid as biocide lubricant oil were used (Flucka, Germany). An
eco-friendly commercial cutting oil denoted as (COM) was
obtained from Indian oil company, India.

biodegradability, thus becoming a source of environmental

pollution in a long term. The major negative effect is
particularly linked to their inappropriate use, which results in 2.2 Methods
surface water and ground water contamination, air pollution, The methodology work in this section was divided into three
soil contamination and, consequently, agricultural product and main steps as follows:
food contamination (Birova et al., 2002). To overcome these 1 formation of cutting oil package;
challenges, various alternatives to petroleum-based MWFs are 2 evaluation of the formulated MWFs as emulsion stability
currently being explored by scientists and tribologists (Ozcelik and corrosion inhibitor; and
et al., 2011). Such alternatives include synthetic lubricants, 3 evaluation of the tribological properties of the formulated
solid lubricants and vegetable-based lubricants. In general, MWFs
vegetable oils are highly attractive substitutes for petroleum-
based oils because they are environmentally friendly, 2.2.1 Formation of cutting oil package
renewable, less toxic and readily biodegradable (Zeman et al., The formulation of cutting oil blend was performed in two
1995; Matthew et al., 2007). Furthermore, the use of vegetable steps as follows:
oils and nontoxic additives increases the possibility to develop a 1 the first step was to formulate the emulsifier package
new generation cutting fluids, where high performance in (emulsifiers, corrosion inhibitor, etc.); and
machining combined with good environment compatibility 2 the second step was to blend the emulsifier package with
could be achieved. Compared to mineral oil, vegetable oil can vegetable base oil (castor oil) to form the finished product
even enhance the cutting performance, extend tool life, and cutting oil package.
improve the surface efficiency (John et al., 2004). Most of the A series of trails and error were carried out to obtain the
studies made in the beginning of this century were on the use of optimum stability of the cutting oil package. In our study, the
new additives and chemical modification of vegetable base oil. cutting oil package consists of vegetable base oil (castor oil),
Antiwear and extreme pressure additives with vegetable oils mixed emulsifier (TS), corrosion inhibitor (MEA), biocide
were used and their tribological performance was evaluated.
Olive and soyabean oils with dibutyl-3,5-di-t-butyl-4-hydroxy Table I Physicochemical properties of cstor oil
benzyl phosphonate (DBP) show dual function of hydrogen
scavenging and protective film formation, thus reducing wear Experiment Value Standard method
(Choi US et al., 1997). The effect of functional additives as oleic Colour Colorless ASTM D-156
acid, triethanolmine and triethanolamineoleate on tribological Density at 15 °C (gm/cm3) 0.950-0.970 IP-160
behavior and thermal stability of rapeseed were studied Iodine number 84.0-88.0 ASTM D4607
(Dmitrieva, 1994). The additives exhibited significantly better Saponification number 176.0-183.0 ASTM D94
tribological behavior and thermal stability. The present work is Acid number <2.0 ASTM D664
an attempt to replace the mineral oil- and synthetic oil-based Kinematics index (cSt) 90.7 ASTM D 445-03
cutting fluids with more eco-friendly alternatives. In addition, Flash Point, °C 296 IP 34/ASTM D93
the investigation will focus on developing functional additives
Castor oil composition
required for cutting fluids which are environmentally benign.
Palmitic acid 2.0 %
The formulated cutting oil emulsions are then tested using a
Stearic acid 3.0 %
unique tribometer which can perform friction testing on freshly
Oleic acid 8.0 %
cut surfaces. In this experimental facility, experiments are Ricinoleic acid 80.0 %
conducted by performing cutting operation inside a pool of the Linoleic acid 3.0 %
lubricant, and friction force is measured in situ.
 Metal working fluid Industrial Lubrication and Tribology
M.R. Noor El-Din et al.

(cinnamon oil) and lubricants oil (oleic acid). Different
percentages of these ingredients were incorporated to optimize
the stability of MWFs as shown in Table II. The evaluation of
the prepared cutting oil was drawn in thermal stability of the
formulated cutting oil.
2.2.1.1 Thermal stability of the soluble oil formulations.
According IP 263, the formulated cutting oil is poured into 100
ml capped bottle test and placed in oven at 70°C for 24 h. At
the end of this period, the oil was examined immediately for any
sign of turbidity, separation or gelling. The blend which gives
stable soluble oil (no gel formation, no separation) was selected
for further investigations (Byers, 2006).
2.2.2 Evaluation of the formulated metal working fluids as emulsion
stability and corrosion inhibitor
2.2.2.1 Emulsion system stability test (screening test). In in a 20
ml standard measuring graduated tube, the MWFs were
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Emulsion stability; %
 
volume of oil separated
¼ 1  100 (1)
Total volume of oil in the emulsion
2.2.2.2 Iron chip corrosion test. According to the standard test
method (ASTM D4627-92), the effect of different corrosion
inhibitors on the stability of MWFs was evaluated. Three types
of corrosion inhibitors namely M, D and E in percentage of 1-3
wt% were added to the cutting oil formulated that succeeded in
step (2.2.2.1) to form three formulated cutting oil packages.
Corrosion tests with cast iron chips were carried out by pouring 4
ml of the MWFs emulsion on 4 gm of washed cast iron chips on a
filter paper in a covered glass container. The cast iron chips were
washed with benzene before use. The rust-preventive effect was
observed visually after 24 h. The rust-prevention effect (the
amount of rust on the cast-iron chips) was rated by the amount of
rust on the filter paper.
The degree of corrosion was estimated on a scale from 0 to

formed by adding the formulated cutting oils and tab water
in percentage of 5 and 95, respectively. The tubes were
vigorously shaken for 2 min, using either hand or a mixer
rotating at 200 rpm for 1 min at 25°C. The emulsion that
formed was then left for 24 h to check the stability visually
(oil and/or cream separations) according to the standard test
method (IP263). Only the milky emulsion which exhibited
remarkable emulsion stability [no separation/no cream after
24 h (ml oil/ml cream = 0/0)] was selected for further
evaluation (Omar, 2004). The emulsion stability (per cent)
was calculated using the following equation:
10. No appearance of rust is denoted as 10; 1 point of rust took
the degree of 9; 2 points of rust took the degree of 8; some
points of rust took the degree of 7; many points of rust took the
degree of 6; many points of rust and stains on the bottom of
watch glass took the degree of 5 (John et al., 2004; Tomoda
et al., 1998).
2.2.2.3 Castor oil droplet size. The average water droplet size
(Zavg) and the oil droplets distribution of the prepared
nanoemulsions were measured at 20°C by dynamic light
scattering (Malvern Zetasizer ZS, Worcestershire, UK) at
scattering angle 173° with an argon laser (k ¼488 nm).

Table II Thermal stability of formulated cutting oils and emulsion stability of MWFs at 70 and 20°C, respectively, and emulsifier’s HLB of 8, pH of 7.14
Ingredient of cutting oil, %
Cutting oil Emulsion stability Thermal stability of
Cutting oil package composition Trial range Optimum range package stability of MWFs at 20 °C* cutting oil at 70 °C
Cutting fluid Package
Castor oil 75-90 87.00 ve ve Homogenous phase (stable)
80.00 ve ve
78.25 ve 1ve
76.5 1ve 1ve
Emulsifier package
Emulsifier (TS) 10-20 10 ve ve Homogenous phase (stable)
15 ve ve
17 ve 1ve
18 1ve 1ve
Corrosion inhibitor (M) 1-3 1.00 ve ve Homogenous phase (stable)
1.50 ve ve
1.75 ve 1ve
2.0 1ve 1ve
Biocide (C) 1-3 1.00 ve ve Homogenous phase (stable)
1.25 ve ve
1.50 ve 1ve
1.75 1ve 1ve
Lubricant oil (O) 1-4 1.00 ve ve Homogenous phase (stable)
1.25 ve ve
1.50 ve 1ve
1.75 1ve 1ve
Notes: *ve: instable emulsion; 1ve: stable emulsion
 Metal working fluid
M.R. Noor El-Din et al.
2.2.3 Evaluating the tribological properties of the formulated metal
working fluids
In this step, the tribological properties of the final formulated
cutting oil composition using the best MWFs emulsion stability
result from step (2.2.2.1) and the best corrosion type result
from step (2.2.2.2) was evaluated. The effective percentage of
the final formulated cutting oil is: castor oil of 76.5 Wt.%,
Emulsifier (TS) of 18 Wt.%, corrosion inhibitor (M) of 2.0
Wt.%, cinnamon oil (biocide) of 1.75 Wt.% and oleic acid
(lubricant oil) of 1.75 Wt.%. The final formulated MWFs is
denoted as E1. Also, a commercial sample denoted as (COM)
based on coconut base oil is used for comparison. Three
methods, namely, tool chip tribometer, drill dynamometer and
surface morphology studies were used to measure the
tribological parameters of E1 and COM. These methods are
briefly explained in experimental section as follows.
2.3 Experimental
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2.3.1 Tool chip tribometer (rotary pin on disk tribometer)
In this step, the performance of the tribological properties for
COM and E1 cutting fluids was evaluated from points of view
of two parameters as coefficient of friction and width of the
wear area on contact between two sliding bodies, blocks, discs
and pin (Anirudhan et al., 2011). To achieve these objectives, a
unique equipment called Tool Chip Trivbometer (rotary pin
on disc tribometer) denoted as POD was used. The schematic
diagram of POD is shown in Figure 1. The experimental setup
of POD is described as follows.
2.3.1.1 Experimental setup. A mild steel disc and high-speed
steel (HSS) tools of type (M) have the following chemical
composition (Wt.%) 0.85 per cent C, 0.28 per cent Mn, 0.30 per
cent Si, 4.15 per cent Cr, 6.15 per cent W, 5.00 per cent Mo, 1.85
per cent Cu and the rest Fe were used. Two different groups of
commercial sample (COM) and E1 cutting fluids were used. The
tool, disc and the friction pin are immersed in cutting fluids bath
during the experiment. Measuring the coefficient of friction
between a pin and a nascent surface was carried out by cutting
metal using a single point tool. To generate the nascent surfaces,
the disc was made to engage against the tool placed in a tank
containing E1 with different dilution of cutting oil. The ratio of
cutting oil to water used in this test is (1:10), (1:20) and (1:40).
Time lag between the instant of cutting and the point of
measurement will depend on the rate per minute (rpm) of the
disc. The disc surfaces at all time remained 2 mm below the liquid
level in the tank. A 3-mm deep and 5-mm wide cut were made. In
situ friction measurements on cut surface have been measured.
Formulations were tested with different set of experiments,
varying one parameter and keeping all other parameters such as
cutting speed or material of work piece constant. The spherical
face radius of the used ball is 3.5 mm. The experiments were
Figure 1 Schematic diagram for the rotary pin on disc tribometer
Industrial Lubrication and Tribology
carried out at 30, 50 and 70 rpm. With these experiments, the
frictional force for a given set of experiments were measured and
analyzed. The better performance in terms of reduced frictional
force and good surface finish was observed by changing the
cutting fluid one by one from COM sample to vegetable oil based
for each set of experiments. The test results are not absolute
values but express the efficiency of the test fluid relative to the
performance of a reference or any other fluid.
2.3.2 Drill dynamometer
Drilling experiments using 10-mm HSS tools were carried out on
a mild steel block. The forces and torques were measured using
appropriate dynamometers. Holes were drilled keeping the work
piece in submerged condition to a depth of 30 mm. Cutting fluids
were applied to the cutting zone through a single flexible hose. The
various combinations of controllable parameters are mentioned in
Table III. Each experiment was repeated for three times.
2.3.3 Surface morphology studies
The surface morphological studies of surface ball and disk surface
were revealed using the scanning electron microscopy (SEM) of
model type JEOL 5410, JEOL, Japan. 3D surface topography
assessment was carried out using 3D profilmeter, Veeco type
WYKO NT1100, USA. The scanning area was 13  4 mm in
axial and circumferential directions, respectively. Scans were
obtained using 200 nm and 7 m m vertical (Z direction) and lateral
(X and Y) resolutions, respectively. Average surface roughness
was measured using Vision software, having a resolution of 0.01
m m. All measurements conformed to ISO4287 and ISO4288
using 0.8 mm cutoff and 4 mm evaluation length. Generally,
Three (Ra) readings (at the beginning, middle and end of the cut)
were recorded and an average was then computed.
3. Results and discussion
3.1 Determination of the optimum hydrophilic-
lipophilic balance value
Generally, surfactant with the right hydrophilic-lipophilic
balance (HLB) value is known to be a key factor for the
formation of stable emulsifier package (Al-Sabagh et al., 2012).
To determine the optimum HLBTS used during this research,
five emulsions consists of 80 Wt.% of castor oil and surfactant
concentration of 20 Wt.% having different HLBTS values of 10,
9.5, 9, 8.5 and 8 were used to optimize the stability of the MWF
formulation. The mixing ratios of (T) and (S) were adjusted to
satisfy the proper HLB values for optimum emulsification
conditions (Noor El-Din et al., 2017b). The mixed HLBTS
values were calculated by the following equation:
HLBTS ¼ ðHLBT  ðTÞ %Þ 1 ðHLBS  ðSÞ%Þ (2)
where; HLBT, HLBS and HLBTS are the HLB values of T
(10.5), S8 (3.7) and the mixed surfactants (TS) and (T)% and
Table III The Standard drilling parameters of the tested cutting fluids
Levels Speed (RPM) Feed (mm/min)
1 [Low] 355 16
0 [Med] 710 25
1 [High] 1120 40
 Metal working fluid Industrial Lubrication and Tribology
M.R. Noor El-Din et al.

(S)% are the mass percentages of T and S in the mixed
surfactants, respectively (Noor El-Din et al., 2017b).
The cutting oil composition composed of emulsifiers
package and base oil (castor oil), without any additives as
corrosion inhibitors, lubricating oil and biocide, was used to
determine the stability of the prepared emulsions visually using
different HLB value. In all, 5 Wt.% of the previous ingredients
was added to water content of 95 Wt.%. In this effort, cutting
fluid package (oil phase)-in-water emulsions which were
observed without any phase separation for 24 h indicates good
stability behavior [see Figures 2(a)-(e)]. The process of
emulsion separation is generally considered to be governed by
three mechanisms as creaming, flocculation and coalescence.
From Figure 2 (a)-(d), it is noticed that the optimum stability
of O/W emulsions without creaming layer separation was
obtained at HLB value of 8. This may be attributed to the
Figure 2 (a-e): Photography of the prepared emulsions with different
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synergism effect between the emulsifiers molecules of types (T)
and (S) adsorbed on the oil–water interface. The presence of
more than one type of surfactant (T) and (S) results in the
formation of rigid interface film around the castor oil droplet.
Accordingly, the interfacial tension between oil and water cause
to reduce. Hence, the possibilities of flocculation and coalescence
of castor oil droplets was decreased (Boyd et al., 1972). Thus, for
further investigation, the optimal HLBTS value used for further
investigation in the following sections is 8.
3.2 Factors affecting the stability of metal working fluid
In this section, the performance of the prepared MWF was
evaluated from points of view of stability of the cutting oil
package and tribological properties as follows:
3.2.1 Stability of cutting oil package
To study the effect of the cutting oil ingredients on the stability
of both cutting oil package and the stability of emulsion of
MWFs, a series of cutting oil formula with different

HLBTS value [(a) 10, (b) 9.5, (c) 9, (d) 8.5 and (e) 8 HLBTS value] at 80 Wt.
% of castor oil and 20 Wt.% TS concentration at working temperature
of 25°C after 24 hour
concentration of emulsifier (TS), corrosion inhibitor (M),
biocide (C) and lubricant oil (O), as well as castor oil (inedible
oil) were formulated at 20°C. The formula that gives stable
cutting oil package (no gel formation, no separation and no sign
of turbidity) was selected for further investigation. The
formulated cutting fluid packages were evaluated according to
the emulsion stability (as explained previously in Section
2.2.2.1). From the preliminary results illustrated in Table IV, it
is noticed that the optimum percentage of cutting oil
ingredients utilized for forming stable MWF is 76.5, 18.0, 2.0,
1.75 and 1.75 Wt.% of castor oil, TS emulsifier, corrosion
inhibitor, biocide and lubricant oil, respectively. The

Table IV Screen test for the stability of metal working fluid oil formulation at emulsifier’s HLB of 8, pH of 7.14 and 20°C
Composition concentration, %
Cutting oil package composition Trial range *Optimum range Cutting oil package stability Emulsion stability
Cutting fluid package
Castor oil 75-90 87.00 ve ve
80.00 ve ve
78.25 ve 1ve
76.5 1ve 1ve
Emulsifier package
Emulsifier (TS) 10-20 10 ve ve
15 ve ve
17 ve 1ve
18 1ve 1ve
Corrosion inhibitor (M) 1-3 1.00 ve ve
1.50 ve ve
1.75 ve 1ve
2.0 1ve 1ve
Biocide (C) 1-3 1.00 ve ve
1.25 ve ve
1.50 ve 1ve
1.75 1ve 1ve
Lubricant oil (O) 1-4 1.00 ve ve
1.25 ve ve
1.50 ve 1ve
1.75 1ve 1ve
Note: *Preliminary optimum MWFs ingredients
 Metal working fluid Industrial Lubrication and Tribology
M.R. Noor El-Din et al.

optimization of each ingredient of the cutting oil package was Figure 3 (a-f): Anti- corrosion properties of the prepared MWFs
revealed as follows: formulation using different corrosion inhibitors as; (a) TEA, (b) DEA and
3.2.1.1 Mixed emulsifier (TS) concentration [(emulsifier/castor (c), (d), (e) and (f) MEA at castor oil/water ratio (1.0/9.0) after 24 hour
oil) molar ratio]. Molar ratio of TS emulsifier to castor oil is one
of the most significant factors affecting the stability of MWF
emulsion (Zimmrman et al., 2003). To understand the effect of
emulsifier concentrations on the stability of MWF emulsion over
24 h, a series of MWFs with different molar ratio of TS emulsifier
ranging from 7.5 to 3.7  104 mole and 9.1  103 mole of
castor oil was used to form a stable emulsion at 2.6  104 mole
of corrosion inhibitor of type MEA and 1.3  102 mole of
cinnamon oil, 6.2  103 mole of oleic acid, HLBTS value of 8,
pH of 7.14 and 20°C. From the obtained results in Table V, it is
cleared that the stability of the performed MWFs diminishes with
decreases the TS concentration. This may be regarded to the
following reasons: increasing in TS concentration result in
increases the total surfactants adsorbed on the castor oil particle,
consequently, the interfacial tension between castor oil and water
cause to reduce and increasing in the surfactants film intensity
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around the castor oil droplet prevents the water droplet from
aggregation (Noor El-Din et al., 2017a). As a result, the optimum
emulsifier concentration that is necessary to form stable emulsion
system is 15 Wt.% (4.9  104 mole) of TS emulsifier and 77.1
Wt.% (9.1  103 mole) of castor oil. Accordingly, the stable
emulsion was obtained by emulsifier/oil molar ratio equal to 1:5.
3.2.1.2 Corrosion inhibitor. Corrosion properties of MWFs
are very important for protecting metal parts that comes in
touch with the fluid (Noor El-Din et al., 2013). To study the cleared that the efficiency of the used inhibitors is ranking as
effect of corrosion inhibitors on the rust formation during the MEA>DEA>TEA, whereas the maximum inhibition efficiency
MWFs working, three types of corrosion inhibitors, namely, was afforded by MEA at concentration of 2.1  104 mole at
triethanolamine (TEA), diethanolamine (DEA) and 25°C. This may be attributed to increasing the number of
monoethanolamine (MEA), were investigated. From the adsorption site and their electron density of MEA. The results
obtained results illustrated in Table VI and Figure 3 (a)-(f), it is illustrated in Table VI show that DEA and TEA have lower

Table V Emulsion stability of the cutting fluid at different molar ratio of TS emulsifier and castor oil at HLBTS of 8, pH of 8.45 and 20°C
Emulsifier (TS), Castor oil, MEA, Cinnamon oil, Oleic acid, Cutting oil Emulsion
mole  104 mole  103 mole  104 mole  102 mole  103 package stability stability
7.5 9.1 2.6 1.3 6.2 1ve 1ve
6.2 9.1 2.6 1.3 6.2 1ve 1ve
4.9 9.1 2.6 1.3 6.2 1ve 1ve
3.7 9.1 2.6 1.3 6.2 1ve ve
Note: ve means creaming formation (1 ml separation)

Table VI anti-Corrosion properties of the best prepared MWFs formula with different types of corrosion inhibitors at 5/95 oil/water emulsion, respectively,
HLB of 8, pH of 7.14 and 20°C after 24 hour
Cutting fluid formula
Anti-corrosion evaluation for (5/95)
Emulsifier Packages Corrosion inhibitor oil-in- water emulsion
TS Emulsifier (TS), mole Oleic acid, mole Castor oil, mole Type Mole Valuation point
4 4
4.9  10 5.6  10 9.1  103 Control 0 0
TEA 8.7  105 5
DEA 1.2  104 6
MEA 1.8  104 7
1.9  104 9
2.1  104 10
Commercial sample 10
 Metal working fluid
M.R. Noor El-Din et al.
inhibition efficiency than that obtained by MEA. This may be
attributed to the effect of the number of terminal (NH2) and
(-OH) groups (Harshida and Mahida, 2012). As a result of
MEA structure, which consists of terminal (NH2), it is probable
that the positive charge (high electron density) of MEA causes a
strong adsorption to the metal surface via electrostatic
interaction between N1 group of MEA and the iron surface (Al-
Sabagh et al., 2013). On the other hand, the number of (-OH)
group as terminal group is considered as another important
factor affecting the inhibitors performance. As a result, the
inhibition efficiency decreases as the number of (-OH) group
increases as follows DEA > TEA. Hence, in TEA inhibitor, the
presence of three (-OH) as withdrawn electron group causes the
electron density of the central amino group to decrease.
Consequently, the adoption of it on the metal surface was
reduced (Harshida and Mahida, 2012). By studying the effect of
MEA concentration on the inhibition efficiency of the prepared
MWFs as shown in Table V and Figure 3 (a)-(f), it was found
that the corrosion inhibition enhances with increasing in the
Downloaded by Indian Institute of Science At 07:59 11 October 2018 (PT)
inhibitor concentration to 2.1  104 mole. This may be
attributed to the increase in MEA concentration causes ability
of inhibitor to cover a large surface area of the metal surface to
raise. Accordingly, the rate of the inhibitor adsorption on the
metal surface was increased (Noor El-din et al., 2016).
3.2.1.3 Effect of cutting oil concentration. The performance of
MWFs was investigated from points of view of emulsification
power, dispersed castor oil droplet size and corrosion inhibition
efficiency to choose the optimum concentration of the used
cutting oil which gives us the best MWF formula. For this
purpose, three MWFs, namely, E1, E2 and E3, were prepared
by mixing various water content as 90, 95 and 97.5 Wt.% with
different concentration of cutting oil as 10, 5 and 2.5 Wt.%,
respectively at 20°C for 24 h. From the obtained results
illustrated in Table VII, it is noticed that the emulsification
power of MWFs decreases with increasing the cutting oil
content. The reason for this phenomenon may be attributed to
emulsifier concentration in the cutting oil package. Therefore,
lowering of cutting oil package (lowest emulsifier
concentration) causes the castor oil droplet size to depress and
the surfactant film intensity around the oil droplet to increase.
Therefore, increase in the surfactants film intensity prevents the
water droplet from aggregation (Noor El-Din et al., 2017b).
Although the minimum castor oil droplet size (PZ) (r = 189.0
nm) and the lowest corrosion inhibitor was obtained in case of
using E3, yet the maximum emulsification efficiency (111ve)
of the used MWFs was gained by E1 as shown in Table VI and
Figure 4 (a)-(c). This may be attributed to the chemical
Table VII Effect of castor oil droplet size on the emulsion stability for
different MWFs at 20°C for 24 h
Emulsion stability
Evaluation test E1 E2
Creaming layer, ml 0 0
Water separation, ml 0 0
Emulsification power 111ve 11ve
Droplet size (Pz), nm 256.7 220.8
Corrosion inhibition efficiency 8 9
(by number)
Industrial Lubrication and Tribology
Figure 4 (a-c): Anti-corrosion properties for the best MWFs at different
concentration of MWFs at 25°C and 7 days
composition of castor oil, which contains about 80-95 per cent
of Ricinoleic acid. As the amount of Recinoleic acid (castor oil
content) in the emulsion increases, the corrosion rate is
expected to increase. Accordingly, the factor that increases the
corrosion rate is not only the type of the corrosion inhibitor but
also the amount of castor oil used in the MWFs (Hiemenz,
1977; Al-Sabagh et al., 2015). Therefore, the emulsification
power of MWFs is depended on not only the formed water
droplet size but also cutting oil concentration.
3.2.2 Machining performance of cutting fluids on mild steel
3.2.2.1 Tool chip tribometer (rotary pin on disk tribometer).
The effect of time (second) on the coefficient of friction (m ) for
commercial cutting fluid (COM) and E1 is shown in Figures 5
and 6. The variation in cut-friction was performed at different
speed of 30, 50 and 70 rpm, normal load of 10 N and for a period
of 140 s. From the obtained results, it is cleared that the
coefficient of friction ( m ) for the investigated MWFs decreases
significantly with decreasing in the cutting speed from 70 to 30
rpm. This observation can be explained as the result of the
formation of boundary fluid film between the ball-pin and the disc
that are driven by the cutting operation (Liu and Erhan, 2005).
Accordingly, the heat produced during sliding and collision
induces the chemical reactions between the nascent surfaces and
MWF, resulting in the formation of a lubricating film (Sokovic
and Mijanovic, 2001; Childers, 1994; Chiffre and Belluco, 2002).
The type of lubricating film formed on the contact surfaces has a
Figure 5 Coefficient of friction variation against time at normal load
10 N and 30 rpm
E3
0
0
1ve
189.0
10
 Metal working fluid
M.R. Noor El-Din et al.
Figure 6 Coefficient of friction variation against time at normal load
10 N and 70 rpm
significant effect on the friction condition and the wear
mechanism. Another explanation of this phenomenon is derived
from the formation of tribofilm on the nascent surfaces.
Generally, in emulsion, at certain diluted concentration close to
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the cmc or at high HLV value, the surfactants molecules
aggregates to form a spherical micelle. In a spherical micelle, an oil
droplet resides encapsulated at the center of the micelle.
Regarding the shear stress and the traction in cutting zone, the oil
inside the micelle releases to the point of cutting to form tribfilm.
Consequently, the lubrication at this zone was increased.
Therefore, in the case of oil-in-water emulsions, the presence of
oil in the core of the micelles causes swelling, which increases the
critical packing parameter (Israelachvili, 1994). Generally, the
chemical structure of the used vegetable oils and surfactants was
affect the film thickness and the adhesion force between the
formed film and the metal substrate. As the thickness and
adherent the film increases at certain load and speed, the
coefficient of friction ( m ) causes to depress (Anirudhan, P. et al.,
2011). At cutting speed of 30 rpm, the minimum coefficient of
fraction (m ) (m = 0.29) was exhibited by E1 while the maximum
coefficient of fraction ( m ) was obtained by COM (m = 0.30).
This may be attributed to the chemical composition of the cutting
oil package and the type of base oil. By inspection of the data
illustrated in Figure 5, it is noticed that coefficient of friction (m )
Figure 7 SEM images of dry ball surface after wearing process at normal load 10 N, and 30 and70 rpm
Industrial Lubrication and Tribology
increases instantaneously to a high value after 70 s. During the
cutting process, the friction remains steady at the higher value
until the time reach to 170 s. When cutting is stopped (by
withdrawing the tool) without interrupting the pin sliding against
the surface, a smooth transition from a state of high friction to low
friction occurs. Figures 7 shows that the surface morphology of
dry balls surface were investigated using SEM to reveal the
wearing during Tool Chip Tribometer process at different cutting
speed as 30 and 70 rpm, load as 10 N for COM and E1. Results
show that a slightly scars on the ball surface was observed at 70
rpm. Also, the scars number increases with increases the cutting
speed from 30 to 70 rpm. This may be explained by that as the
speed of pin in the nascent surface increases, the temperature at
this edge was increased. As a result, the adsorption of the cutting
fluid on the nascent surface decreases which in turn leads to form
scars on the ball surface.
3.2.2.2 Drill dynamometer. Drilling can be described as a
process where a multi-point tool is used to remove unwanted
materials to produce a hole. Chip shape is the most important
factor for the smoothness of a drilling process. The drilling
process will be smooth if chips are well broken (Anil, 2012). The
machining properties as cutting forces (Fc) and cutting torque
(FT) for untreated HSS block (dry) and treated HSS block using
two types of cutting fluids namely; COM and E1 was evaluated
as shown in Figures 8 and 9. Three drilling parameters with three
levels were selected to perform the drilling dynamometer
experiments as shown in Table VIII. From the obtained results
illustrated in Figures 8 and 9, the following points are noticed:
 The highest cutting force and cutting torque was observed
with dry cutting for drilling parameters.
 Significant cutting force variations are observed for dry
cutting and investigated cutting fluids. This may be
because of the formation of built-up-edge or clogging of
chips at the cutting zone (Siniawski et al., 2007).
 At constant depth of cut, (Fc) and (FT) decrease with the
increase in the cutting speed from 355 to 1,120 rpm.
 From Figures 8 and 9, comparing to the commercial
cutting fluid (COM) and cutting torque (FT), it is
observed that the lowest cutting force (Fc) was obtained
 Metal working fluid
M.R. Noor El-Din et al.
Figure 8 Effect of drilling speed and cutting feed force on the actual force using dry, COM and E1 cutting fluids
Figure 9 Effect of drilling force and cutting force on the cutting torque using dry, COM and E1 cutting fluids
Downloaded by Indian Institute of Science At 07:59 11 October 2018 (PT)
Table VIII Drilling dynamometer parameters with their levels
Drilling parameters Level 1 Level 2
Cutting speed, rpm 355 710
Cutting feed force, m/min 4 and 10 4 and 10
Depth of cut, mm 30 30
by E1 at cutting speed as 355, 710 and 1,120 rpm and
cutting feed force as 4 and 10 m/min. This may be
attributed to nature of the vegetable oil and the chemical
structure of the said cutting fluids.
 In few combinations of speed and feed rates, lower cutting
force (Fc) and higher cutting torque (FT) values were
recorded with E1 compared to COM. During the cutting
operations, sometimes the chips formed between the
machine tool and work species may prevent or obstruct
the cutting fluid from reaching the cutting zone, which
further may affect the force and torque. Also, the
generated chips shape and its thickness will be directly
influence on the ability of cutting fluid to reach and cover
the chip- tool interaction zone (Jun et al., 2008).
3.2.2.3 3D surface topography. The influence of COM and E1
cutting fluids on the surface roughness (Ra) of the steel cutting
Industrial Lubrication and Tribology
surface disc at different cutting speed as 30, 50 and 70 rpm and
cutting feed force as 4 m/min was shown in Figure 10. From the
Level 3 obtained results, it is observed that the maximum (Ra) of 2.56
m m was achieved by dry cutting. For cutting fluid (E1), lowering
1120 of cutting speed from 70 to 30 rpm causes surface roughness (Ra)
4 and 10 to rise from 970.70 nm to 2.56 m m. This may be regarded to the
30 exposure time of the freshly cut surface to the cutting fluid, which
was decreased by time. Consequently, the adsorption of the
cutting fluid on the cutting zone was increased. Which in turn,
the greatest protection of the cutting zone cause the roughness
(Ra) of the cutting surface to decrease. Generally, the surface
roughness as a function of feed rate of the drilling tool and the
drilling speed can be summarized as follows:
 At drilling speed with an increase of feed rate of drilling,
the surface roughness increases.
 At constant force and drilling feed rate, the surface
roughness will decrease with increase in the drilling speed.
7. Conclusion
In this paper, a new formulated eco-friendly cutting oil based on
castor oil was prepared to decrease the environmental impact
during utilize of cutting machines. Two unique aspects, apart
from the eco-friendly aspects of the emulsion, as using of newly
formulated emulsifiers and evaluation of the “effectiveness” of
 Metal working fluid
M.R. Noor El-Din et al.
Figure 10 3D optical profilometer for E1 and COM cutting fluids at
cutting speed as 30, 50 and 70 rpm
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the new formulation using a newly developed method called the
tool-chip tribometer were discussed. From the obtained results, it
is concluded that the prepared eco-friendly emulsion exhibited a
high stability over a long time up to 14 days and small particle size
(189.0 nm). Also, the effect of MWFs on the machine
performance was investigated. Results show that the minimum
and the maximum friction coefficient (COF) as 0.29 and 0.30
were obtained by E1 and COM, respectively. Also, it is noticed
that the (Ra) of E1 increases from 0.970 to 2.56 m m with the
increase in the rotating speed from 30 to 50 rpm.
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Corresponding author
M.R. Noor El-Din can be contacted at: mrned04@yahoo.
com