Tribological characterization of a new microemulsion cutting fluid formetal processing

Purpose A microemulsion cutting fluid represents an extremely effective material for the processing of metals. However, the stability and lubricity of microemulsion cutting fluids are constrained by conventional functional additives. The purpose of this study is to formulate a novel microemulsion cutting fluid. Design/methodology/approach In this study, an innovative microemulsion cutting fluid was developed through the interfacial complex generation method. The coefficient of friction of the cutting fluid was evaluated using a four-ball friction tester and reciprocating ball-on-disk tribometer. Findings The findings show that the novel microemulsion cutting fluid exhibited a stable micro emulsification state and formed a nanoscale oil-in-water structure. Concurrently, the adsorption film formed during the sliding process can effectively mitigate wear over an extended duration, thus attaining superior lubricating efficacy. Originality/value The recently developed microemulsion cutting fluid displays notable stability and lubricity, suggesting promising avenues for the advancement of high-performance microemulsion cutting fluids in future metal processing applications. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2025-0301/