Sustainable manufacturing is making products from processes which have minimal environmental impact, energy and resource efficient, economically viable and safe for consumers and society as whole. Achieving sustainability in manufacturing would mean infusing sustainability methods on product process and system level. On the process level, machining technology is one of the most widely extended processes in the industry. One way to attain sustainability in this technology is by adopting efficient management of Metal Working Fluids (MWF). In this purpose to reduce the amount of MWF starts Minimum Quantity Lubrication (MQL), where very small quantity of fluid is applied to the cutting zone with maximum precision. Moreover, addition of nanoparticles to these ´minimum quantity lubricants´ further enhances its tribological properties leading to higher reduction in friction and temperature in the machining process.The main objective of this thesis is to study the performance of cooling-lubricating fluids and these fluids modified with nanoparticles, how the use of this new lubricants improves the results obtained in material process technologies, particularly in turning. This project is being supported by the company LetsNano AB, providing the lubricants enhanced with nanoparticles and the funding, and Accu-Svenska AB, providing base oil and MQL technology.The experiments are carried out at Kungliga Tekniska Högskolan (KTH), at Institutionen för Industriell Produktion (IIP) laboratory. The turning process was tested with two different workipiece materials: hardened steel (Toolox® 44) provided by SSAB, and grey cast iron (Scania case study material). Two different tooling systems, due to the different materials. One provided by Mircona AB, and the other given directly by Scania, provided by Sandvik AB and Cermatec AB. The MQL system is a high-performance booster provided by Acuu-Svenska AB. The lubricant is a vegetable oil that will also be the base for the Nanofluids (NF). This Nanofluids and produced and developed by LetsNanoAB.The study revealed an encouraging potential of moving from conventional (dry) cooling techniques to the vegetable oil based MQL. Machining performance of MQL was encouraging as in most of the cases the systematic reduction in tool wear reveals a better machinability. The contribution of this work for Scania could help them to take the decision and move to more sustainable machining processes. To prove the potential of the nanotechnology in this kind of processes further study is needed, and it is going to be tested at IIP facilities in near future. The implementation of this technology brings more challenges that should considered a study of the hazards of the technology (emissions, fire and explosion, noise, skin…) necessary safety measures (cleaning, operator instruction, skin protection…) and modifications in the machine tools system beyond the process only. This could also be a next step in the further study of this research. / Hållbar tillverkning gör produkter från processer som har minimal miljöpåverkan, energi och resurseffektiv, ekonomiskt genomförbar och säker för konsumenterna och samhället som helhet. Att uppnå hållbarhet i tillverkningen skulle innebära infusion av hållbarhetsmetoder på produktprocess och systemnivå. På processnivå är bearbetningsteknologi en av de mest utbredda processerna inom branschen. Ett sätt att uppnå hållbarhet i denna teknik är genom att anta effektiv hantering av metallbearbetningsvätsko (MWF). I detta syfte för att minska mängden MWF startas Minimalsmörjning (MQL), där mycket liten mängd vätska appliceras på skärzonen med maximal precision. Dessutom ökar tillsatsen av nanopartiklar till dessa "minimala smörjmedel" ytterligare sina tribologiska egenskaper vilket leder till högre minskning av friktion och temperatur i bearbetningsprocessen.Huvudsyftet med denna avhandling är att studera prestanda av kylsmörjande vätskor och dessa vätskor modifierade med nanopartiklar, hur användningen av de här nya smörjmedlen förbättrar resultaten som erhållits i materialteknik, särskilt vid vridning. Projektet stöds av företaget LetsNano AB, vilket ger smörjmedlen förbättrad med nanopartiklar och finansieringen, och Accu-Svenska AB, som erbjuder basolja och MQL-teknik.Experimenten utförs vid Kungliga Tekniska Högskolan (KTH) vid Institutionen för Industriell Produktion (IIP). Vridprocessen testades med två olika material: Härdat stål (Toolox® 44) som SSAB levererade och grått gjutjärn (Scanias fallstudiematerial). Två olika verktygssystem, på grund av olika material. En som tillhandahålls av Mircona AB och den andra som ges direkt av Scania, tillhandahållen av Sandvik AB och Cermatec AB. MQL-systemet är en högpresterande booster som tillhandahålls av Acuu-Svenska AB. Smörjmedlet är en vegetabilisk olja som också kommer att vara basen för Nanofluiderna (NF). Dessa Nanofluider och produceras och utvecklas av LetsNanoAB.Studien avslöjade en uppmuntrande potential att flytta från konventionell (torr) kylningsteknik till den vegetabiliska oljebaserade MQL. Maskinens bearbetningsförmåga var uppmuntrande, eftersom i de flesta fallen den systematiska minskningen av verktygsslitaget visar bättre bearbetning. Arbetet med detta arbete för Scania kan hjälpa dem att fatta beslut och flytta till mer hållbara bearbetningsprocesser. För att bevisa nanoteknikens potential i denna typ av processer krävs ytterligare studier, och det kommer att bli testat vid IIP-anläggningar inom en snar framtid. Genomförandet av denna teknik ger fler utmaningar som bör övervägas en studie av farorna med tekniken (utsläpp, brand och explosion, buller, hud ...) nödvändiga säkerhetsåtgärder (rengöring, operatörsinstruktion, skydd mot huden ...) och modifikationer i verktygsmaskinerna system utöver processen bara. Detta kan också vara nästa steg i den fortsatta studien av denna forskning.

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Lubrication theory plays a fundamental role in all mechanical design as well as applications to biomechanics. All machinery are composed of moving parts which must be protected against wear and damage. Without effective lubrication, maintenance cycles will be shortened to impractical levels resulting in increased costs and decreased reliability. The focus of the work presented here is on the lubrication of rotating machinery found in advanced power systems and designs involving micro-turbines. One of the earliest studies of lubrication is due to Osborne Reynolds in 1886 who recorded what is now regarded as the canonical equation governing all lubrication problems; this equation and its extensions have become known as the Reynolds equation. In the past century, Reynolds equation has been extended to include three-dimensional effects, unsteadiness, turbulence, variable material properties, non-newtonian fluids, multi-phase flows, wall slip, and thermal effects. The bulk of these studies have focused on highly viscous liquids, e.g., oils. In recent years there has been increasing interest in power systems using new working fluids, micro-turbines and non-fossil fuel heat sources. In many cases, the design of these systems employs the use of gases rather than liquids. The advantage of gases over liquids include the reduction of weight, the reduction of adverse effects due to fouling, and compatibility with power system working fluids. Most treatments of gas lubrication are based on the ideal, i.e., low pressure, gas theory and straightforward retro-fitting of the theory of liquid lubrication. However, the 21st Century has seen interest in gas lubrication at high pressures. At pressures and temperatures corresponding to the dense and supercritical gas regime, there is a strong dependence on gas properties and even singular behavior of fundamental transport properties. Simple extrapolations of the intuition and analyses of the ideal gas or liquid phase theory are no longer possible. The goal of this dissertation is to establish the correct form of the Reynolds equation valid for both low and high pressure gases and to explore the dynamics predicted by this new form of the Reynolds equation. The dissertation addresses five problems involving our new Reynolds equation. In the first, we establish the form appropriate for the simple benchmark problem of two-dimensional journal bearings. It is found that the material response is completely determined by a single thermodynamic parameter referred to as the "effective bulk modulus". The validity of our new Reynolds equation has been established using solutions to the full Navier-Stokes-Fourier equations. We have also provided analytical estimates for the range of validity of this Reynolds equation and provided a systematic derivation of the energy equation valid whenever the Reynolds equation holds. The next three problems considered here derive local and global results of interest in high speed lubrication studies. The results are based on a perturbation analysis of our Reynolds and energy equation resulting in simplified formulas and the explicit dependence of pressure, temperature, friction losses, load capacity, and heat transfer on the thermodynamic state and material properties. Our last problem examines high pressure gas lubrication in thrust bearings. We again derive the appropriate form of the Reynolds and energy equations for these intrinsically three-dimensional flows. A finite difference scheme is employed to solve the resultant (elliptic) Reynolds equation for both moderate and high-speed flows. This Reynolds equation is then solved using perturbation methods for high-speed flows. It is found that the flow structure is comprised of five boundary layer regions in addition to the main ``core'' region. The flow in two of these boundary layer regions is governed by a nonlinear heat equation and the flow in three of these boundary layers is governed by nonlinear relaxation equations. Finite difference schemes are employed to obtain detailed solutions in the boundary layers. A composite solution is developed which provides a single solution describing the flow in all six regions to the same accuracy as the individual solutions in their respective regions of validity. Overall, the key contributions are the establishment of the appropriate forms of the Reynolds equation for dense and supercritical flows, analytical solutions for quantities of practical interest, demonstrations of the roles played by various thermodynamic functions, the first detailed discussions of the physics of lubrication in dense and supercritical flows, and the discovery of boundary layer structures in flows associated with thrust bearings. / Doctor of Philosophy / Lubrication theory plays a fundamental role in all mechanical design as well as applications to biomechanics. All machinery are composed of moving parts which must be protected against wear and damage. Without eective lubrication, maintenance cycles will be shortened to impractical levels resulting in increased costs and decreased reliability. The focus of the work presented here is on the lubrication of rotating machinery found in advanced power systems and designs involving micro-turbines. One of the earliest studies of lubrication is due to Osborne Reynolds in 1886 who recorded what is now regarded as the canonical equation governing all lubrication problems; this equation and its extensions have become known as the Reynolds equation. In the past century, Reynolds equation has been extended to include three-dimensional eects, unsteadiness, turbulence, variable material properties, non-newtonian uids, multi-phase ows, wall slip, and thermal eects. The bulk of these studies have focused on highly viscous liquids, e.g., oils. In recent years there has been increasing interest in power systems using new working uids, micro-turbines and non-fossil fuel heat sources. In many cases, the design of these systems employs the use of gases rather than liquids. The advantage of gases over liquids include the reduction of weight, the reduction of adverse eects due to fouling, and compatibility with power system working uids. Most treatments of gas lubrication are based on the ideal, i.e., low pressure, gas theory and straightforward retro-tting of the theory of liquid lubrication. However, the 21st Century has seen interest in gas lubrication at high pressures. At pressures and temperatures corresponding to the dense and supercritical gas regime, there is a strong dependence on gas properties and even singular behavior of fundamental transport properties. Simple extrapolations of the intuition and analyses of the ideal gas or liquid phase theory are no longer possible. The goal of this dissertation is to establish the correct form of the Reynolds equation valid for both low and high pressure gases and to explore the dynamics predicted by this new form of the Reynolds equation. The dissertation addresses ve problems involving our new Reynolds equation. In the rst, we establish the form appropriate for the simple benchmark problem of two-dimensional journal bearings. It is found that the material response is completely determined by a single thermodynamic parameter referred to as the eective bulk modulus. The validity of our new Reynolds equation has been established using solutions to the full Navier-Stokes-Fourier equations. We have also provided analytical estimates for the range of validity of this Reynolds equation and provided a systematic derivation of the energy equation valid whenever the Reynolds equation holds. The next three problems considered here derive local and global results of interest in high speed lubrication studies. The results are based on a perturbation analysis of our Reynolds and energy equation resulting in simplied formulas and the explicit dependence of pressure, temperature, friction losses, load capacity, and heat transfer on the thermodynamic state and material properties. Our last problem examines high pressure gas lubrication in thrust bearings. We again derive the appropriate form of the Reynolds and energy equations for these intrinsically threedimensional ows. A nite dierence scheme is employed to solve the resultant (elliptic) Reynolds equation for both moderate and high-speed ows. This Reynolds equation is then solved using perturbation methods for high-speed ows. It is found that the ow structure is comprised of ve boundary layer regions in addition to the main core region. The ow in two of these boundary layer regions is governed by a nonlinear heat equation and the ow in three of these boundary layers is governed by nonlinear relaxation equations. Finite dierence schemes are employed to obtain detailed solutions in the boundary layers. A composite solution is developed which provides a single solution describing the ow in all six regions to the same accuracy as the individual solutions in their respective regions of validity. Overall, the key contributions are the establishment of the appropriate forms of the Reynolds equation for dense and supercritical ows, analytical solutions for quantities of practical interest, demonstrations of the roles played by various thermodynamic functions, the rst detailed discussions of the physics of lubrication in dense and supercritical ows, and the discovery of boundary layer structures in ows associated with thrust bearings.