Eco-Friendly Drilling of AA 5052-H32 Alloy: Influence of Jasmine-Based Cutting Fluid on Surface Quality and Burr Formation

The aerospace and automotive sectors are increasingly emphasizing sustainable production, requiring environmentally benign methods for machining activities. This study examines a biodegradable cutting fluid composed of 85% jasmine oil and 15% organic petroleum-based additives as an eco-friendly substitute for traditional lubricants in the drilling of AA 5052-H32 aluminum alloy, a material widely utilized in structural applications. Response Surface Methodology (RSM) was employed to examine the impacts of cutting speed and feed rate on surface quality, burr development, and temperature, based on 27 experimental observations across three lubrication conditions: dry, 90 − 10% water-to-oil, and 80 − 20% water-to-oil mixes. Findings indicate that increased cutting speeds and appropriate feed rates markedly improve surface quality, attaining a minimal surface roughness of 7.3 µm at 6370 rpm and 2867 mm/min under the 80 − 20% coolant condition. This lubrication regime exhibited the least burr height of 0.07 mm and the most efficient cooling, with a lowest temperature of 33.8°C. In comparison, dry drilling demonstrated subpar performance, characterized by heightened burr height and surface roughness resulting from raised tool temperatures and material deformation. Also, jasmine-based cutting fluid enhances machining performance by improving temperature and lubricating characteristics, minimizing environmental impact, and promoting sustainability in precision drilling operations. This research emphasizes the significance of parameter optimization for attaining enhanced hole quality while advocating for a shift towards ecologically sustainable production processes. Future research is advised to investigate the prolonged impacts of biodegradable lubricants on tool longevity and their compatibility with various machining processes and materials.