Processing Performance and Optimization of Electrostatic Atomization Cutting of Aluminum Alloy Using Graphene Oxide Water-based Nanofluids

SU Yu; WU Minghao; QIU Shuoshuo; LIU Pan; CHU Zepeng

doi:10.16490/j.cnki.issn.1001-3660.2026.15.010

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Surface Technology ›› 2026, Vol. 55 ›› Issue (15) : 123-137. DOI: 10.16490/j.cnki.issn.1001-3660.2026.15.010

Processing Performance and Optimization of Electrostatic Atomization Cutting of Aluminum Alloy Using Graphene Oxide Water-based Nanofluids

SU Yu^1,*, WU Minghao¹, QIU Shuoshuo¹, LIU Pan², CHU Zepeng³

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Abstract

Water-based nanofluid electrostatic spray can effectively improve the utilization rate of water-based nanofluids and enhance the processing performance by using high-voltage electrostatic field to transport charged droplets to the processing area. However, at present, the electrostatic spray cutting performance using water-based nanofluids has not been studied, and there is a lack of understanding of its relationship with charging performance and wettability. Therefore, it is urgent to carry out relevant works. The mode, charging performance, and wettability for electrostatic spray using graphene oxide water-based nanofluids are tested in this work. The single factor and orthogonal test methods are used to carry out the electrostatic spray cutting of aluminum alloy with graphene oxide water-based nanofluids. Based on the test results of spray current and charged droplet's surface tension and contact angle, the effects of voltage, graphene oxide content, and flow rate on cutting force and surface temperature of the cutting zone are studied. The graphene oxide content, flow rate, and cutting speed are optimized by using signal-to-noise ratio and grey correlation analysis method, so as to reduce the force and the temperature effectively. In addition, the tool wear test and machined surface quality inspection for electrostatic spray cutting with deionized water, graphene oxide water-based nanofluid, and LB2000 vegetable lubricating oil under the optimal parameters are carried out to further confirm the processing effect of the optimal parameters. The spray test results show that conical jet is a spray mode for continuous cooling and lubrication of cutting edges. The spray current of electrostatic spray using graphene oxide water-based nanofluids is higher than that of deionized water electrostatic spray, while the surface tension and contact angle of charged droplets are lower compared with deionized water electrostatic spray. The increase of voltage, graphene oxide content, and flow rate can easily lead to the improvement of charging performance and wettability. The single factor cutting test results indicate that compared with deionized water electrostatic spray, the cutting force and surface temperature of the cutting zone for electrostatic spray using graphene oxide water-based nanofluids are reduced by 1.59%-6.71% and 0.54%-13.87%, respectively. The changing trends of cutting force and surface temperature in the cutting zone with voltage and graphene oxide content are affected by the charging and wetting properties, spray dispersion, and the fluidity and dispersion of graphene oxide water-based nanofluids. The signal-to-noise ratio and grey correlation analysis for the orthogonal experimental results suggest that in terms of the comprehensive effect of reducing the cutting force and the surface temperature of the cutting zone, the optimal graphene oxide content, flow rate, and cutting speed are 0.3vol.%, 5 mL/h, and 353 m/min, respectively. Compared with deionized water electrostatic spray and LB2000 vegetable oil electrostatic spray, the tool wear and machined surface roughness under the optimal parameters are lowered by 27.8%-30.8% and 7.7%-31.5%, respectively. The addition of graphene oxide not only improves the electrostatic spray effect and wettability, but also deposits on the cutting surface to form a lubricating layer, thus improving the cooling and lubrication performance and consequently enhancing the processing performance of aluminum alloy cutting.

Key words

aluminum alloy / cutting / graphene oxide water-based nanofluid / electrostatic atomization / minimal quantity lubrication

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SU Yu, WU Minghao, QIU Shuoshuo, LIU Pan, CHU Zepeng. Processing Performance and Optimization of Electrostatic Atomization Cutting of Aluminum Alloy Using Graphene Oxide Water-based Nanofluids[J]. Surface Technology. 2026, 55(15): 123-137

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