Morphology of surface generated by end milling AL6061-T6 using molybdenum disulfide (MoS2) nanolubrication in end milling machining

•The nano-lubricants were prepared by suspending the MoS2 nanoparticles in oil.•To supply the nano-lubricants, MQL system was used with a nozzle diameter of 1 mm.•The existence of MoS2 nanoparticles improved the quality of machined surface.•The MoS2 nanoparticles impart their effects by rolling, filling and polishing action.•MoS2 suspended nano-lubricant is an excellent alternative for perfect surface quality.

Aluminum alloys are among the most significant metals in industries. The AL6061-T6 aluminum alloy is a highly prominent alloy due to its dominant mechanical properties, such as weldability, hardness and sustainability at high temperatures. AL6061-T6 is commonly used in heavy industries including aerospace, aircraft, automotive, food packaging, etc. Milling of AL6061-T6 is important, especially to create product shape varieties for different applications. However, the demand for high quality draws attention to product quality, particularly machined surface roughness, as it directly affects the product's appearance, function and reliability. Applying correct lubrication to the machining zone can enhance the tribological characteristics of AL6061-T6 alloy. For further improvement, introducing nanolubricant may yield superior product quality due to the rolling action of nanoparticles at the tool-workpiece interface, which significantly reduces cutting force. In this research work, a nanolubricant containing MoS2 nanoparticles is developed for end milling of AL6061-T6 alloy and the surface morphology of the machined workpiece is investigated as well.