Optimization of MQL Parameters using Computational Fluid Dynamics for Enhanced High Speed Machining of AISI 4340 Steel

Optimization of MQL Parameters using Computational Fluid Dynamics for Enhanced High Speed Machining of AISI 4340 Steel | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Optimization of MQL Parameters using Computational Fluid Dynamics for Enhanced High Speed Machining of AISI 4340 Steel Haniff Abdul Rahman, Jaharah A. Ghani, Mohamad Rasidi Mohammad Rasani, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8202927/v1 This work is licensed under a CC BY 4.0 License Status: Under Revision Version 1 posted 5 You are reading this latest preprint version Abstract This study addresses the challenge of thermal management in high-speed machining of hardened AISI 4340 steel by investigating the effectiveness of Minimum Quantity Lubrication (MQL) as a sustainable alternative to conventional cooling. Although MQL offers environmental and safety benefits, its restricted cooling capacity can limit its effectiveness for hard-to-cut alloys. Using computational fluid dynamics (CFD) simulation, this work systematically explores the influence of MQL parameters specifically oil flow rate, F (50–150 ml/h), nozzle distance, D (20–40 mm), and nozzle angle, A (30–60°) on temperature generated at the cutting zone. Temperature boundary conditions from finite element analysis (FEA) at a cutting speed, V = 400 m/min; feed, f = 0.1 mm/rev; and depth of cut, d = 0.2 mm were applied. Experimental turning tests validated the simulation results, with cutting temperature deviations of 8% and 10% for dry and MQL conditions, respectively. The optimal MQL configuration (50 ml/h oil flow, 20 mm nozzle distance, 30° nozzle angle) was identified, with nozzle angle exerting the greatest influence on temperature control. Compared to dry cutting, this optimal MQL setup reduced cutting temperature by 32%, cutting force by 28%, and surface roughness by 11.9%, resulting in an estimated 22% increase in tool life. These findings affirm that optimizing MQL parameters can substantially improve cooling efficiency and machinability in high-speed machining and hard turning of AISI 4340 steel, supporting further advances in sustainable, high-performance manufacturing. Minimum Quantity Lubrication Computational Fluid Dynamic High Speed Machining AISI 4340 Full Text Cite Share Download PDF Status: Under Revision Version 1 posted Editorial decision: Major Revisions Needed 30 Apr, 2026 Reviewers agreed at journal 10 Feb, 2026 Reviewers invited by journal 08 Feb, 2026 Editor assigned by journal 01 Dec, 2025 First submitted to journal 29 Nov, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8202927","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":587723403,"identity":"9c8ba7d0-eb91-490a-8825-fed85a5896ac","order_by":0,"name":"Haniff Abdul Rahman","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAABBElEQVRIiWNgGAWjYDACZsbGBx94bOQYmCF8AxAhgVcLO3Oz4QyZNGMStPCzt0nz2BxObGAgVos5M2ObBE9OWvr8dvZnEj8YDhvrNjAfvM3DsA1uCDqwbGZstpA4Y5O74TCPmWQPw2EzswNsydY8DLdxajE4zNh4w7AnLXcDMw/bDR6GwzZmB3jMpAloaZBI/Hc4Xb6Z/dnNP2At/N8IaWmSOMBzOIHhMIMZ0Asgh/Gw4dUC8othA0+aIdAv5r9lDNKNzQ6zGVvOMbhtjEuLOf/xh4//8NjIy/cff2z4psLacNvx5oc33lTclsXpMEwuM4ThSKQWJGCPU2YUjIJRMApGGgAALJJWNDlD6bYAAAAASUVORK5CYII=","orcid":"https://orcid.org/0000-0001-6774-5208","institution":"Universiti Kebangsaan Malaysia","correspondingAuthor":true,"prefix":"","firstName":"Haniff","middleName":"Abdul","lastName":"Rahman","suffix":""},{"id":587723404,"identity":"e1950d2e-608f-40f9-ace1-3a731063c5db","order_by":1,"name":"Jaharah A. 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Although MQL offers environmental and safety benefits, its restricted cooling capacity can limit its effectiveness for hard-to-cut alloys. Using computational fluid dynamics (CFD) simulation, this work systematically explores the influence of MQL parameters specifically oil flow rate, \u003cem\u003eF\u003c/em\u003e (50\u0026ndash;150 ml/h), nozzle distance, \u003cem\u003eD\u003c/em\u003e (20\u0026ndash;40 mm), and nozzle angle, \u003cem\u003eA\u003c/em\u003e (30\u0026ndash;60\u0026deg;) on temperature generated at the cutting zone. Temperature boundary conditions from finite element analysis (FEA) at a cutting speed, \u003cem\u003eV\u003c/em\u003e\u0026thinsp;=\u0026thinsp;400 m/min; feed, \u003cem\u003ef\u003c/em\u003e\u0026thinsp;=\u0026thinsp;0.1 mm/rev; and depth of cut, \u003cem\u003ed\u003c/em\u003e\u0026thinsp;=\u0026thinsp;0.2 mm were applied. Experimental turning tests validated the simulation results, with cutting temperature deviations of 8% and 10% for dry and MQL conditions, respectively. The optimal MQL configuration (50 ml/h oil flow, 20 mm nozzle distance, 30\u0026deg; nozzle angle) was identified, with nozzle angle exerting the greatest influence on temperature control. Compared to dry cutting, this optimal MQL setup reduced cutting temperature by 32%, cutting force by 28%, and surface roughness by 11.9%, resulting in an estimated 22% increase in tool life. These findings affirm that optimizing MQL parameters can substantially improve cooling efficiency and machinability in high-speed machining and hard turning of AISI 4340 steel, supporting further advances in sustainable, high-performance manufacturing.\u003c/p\u003e","manuscriptTitle":"Optimization of MQL Parameters using Computational Fluid Dynamics for Enhanced High Speed Machining of AISI 4340 Steel","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-02-12 06:27:35","doi":"10.21203/rs.3.rs-8202927/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Major Revisions Needed","date":"2026-05-01T03:34:44+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2026-02-10T07:08:49+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2026-02-08T13:58:11+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-12-02T04:49:46+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-11-29T19:51:27+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"4e90f470-df7a-4c08-9475-ef89f04b0e1a","owner":[],"postedDate":"February 12th, 2026","published":true,"recentEditorialEvents":[{"type":"decision","content":"Major Revisions Needed","date":"2026-05-01T03:34:44+00:00","index":"","fulltext":""}],"rejectedJournal":[],"revision":"","amendment":"","status":"in-revision","subjectAreas":[],"tags":[],"updatedAt":"2026-05-01T07:35:00+00:00","versionOfRecord":[],"versionCreatedAt":"2026-02-12 06:27:35","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-8202927","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8202927","identity":"rs-8202927","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}