Browsing by Author "Sarfraz, Shoaib"
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Item Open Access Benchmark pre-production practice in manufacturing engineering(IOS Press, 2017-12-31) Shehab, Essam; Rao, Yogeesh; Al-Ashaab, Ahmed; Beadle, Chris; Sarfraz, ShoaibPrototyping stage is a very important phase of new product development, where many decisions need to be taken to get high quality, zero defect products at the right time with minimum cost. Therefore, any value added improvements or best practices in the prototyping stage will support competitiveness of manufacturing companies. This research aims to benchmark the best practices in prototype part manufacture to support early stages of product introduction. A set of of best practices in the prototype component manufacture, along with validated four step prototyping strategy model and best practice prototype journey path model were developed. Research findings provide insight about prototyping trends, best practices and optimum ways of doing prototyping in the manufacturing companies around the globe. Manufacturing companies can use the developed models and best practices to make better prototype strategy in their new product introduction system to achieve their business objectives.Item Open Access Benchmarking of energy consumption and CO2 emissions in cement production: a case study(Springer, 2024-02-02) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark; Salonitis, KonstantinosIn the pursuit of economic growth and value creation, foundation industries including cement, metals, glass, chemicals, paper, and ceramics face formidable challenges related to energy usage, emissions, and resource consumption in their manufacturing operations, all while striving to achieve ambitious Net Zero carbon and green targets. To overcome these challenges and propel sustainable progress, benchmarking emerges as a powerful ally. This study performs a benchmarking analysis of energy use and CO2 emissions for a UK cement plant as well as best available techniques (BAT) investigation to identify opportunities for performance improvement in crucial areas such as energy usage and environmental sustainability. The research utilises industrial data from a 2850 tonne per day capacity dry process cement plant. Key energy and emissions parameters, including thermal and electrical energy intensity, recovered energy and CO2 intensity, are computed per tonne of cement produced along with capacity utilisation across major process stages including raw material grinding, clinkerisation, and cement grinding. Comprehensive data sourced directly from the manufacturer is compared against literature benchmarks for global averages and best practices. Although surpassing global average values, the plant lags European best practices across all metrics, signalling room for substantial improvement. Assessment of relevant BATs for the cement industry reveals prospects to integrate vertical roller mills for cement grinding and use Organic Rankine Cycle (ORC) at the clinkerisation stage. Adopting these techniques could reduce the electrical energy intensity of clinkerisation by 51% and cement grinding electrical intensity by 30%, surpassing benchmarks. While limited to a single cement plant, the study provides a standardised methodology that could be replicated across foundation industries to enable performance tracking and highlight efficiency gaps. The benchmarking approach developed can guide the implementation of energy conservation measures and the adoption of best practices by the cement industry to reduce its carbon footprint.Item Open Access Chapter 5: Comprehensive study on tool wear during machining of fiber-reinforced polymeric composites(Springer, 2020-12-23) Ismail, Sikiru Oluwarotimi; Sarfraz, Shoaib; Niamat, Misbah; Mia, Mozammel; Gupta, Munish Kumar; Pimenov, Danil Yu; Shehab, EssamThe use of fiber reinforced polymeric (FRP) composites has increased rapidly, especially in many manufacturing (aerospace, automobile and construction) industries. The machining of composite materials is an important manufacturing process. It has attracted several studies over the last decades. Tool wear is a key factor that contributes to the cost of the machining process annually. It occurs due to sudden geometrical damage, frictional force and temperature rise at the tool-work interaction region. Moreover, tool wear is an inevitable, gradual and complex phenomenon. It often causes machined-induced damage on the workpiece/FRP composite materials. Considering the geometry of drill, tool wear may occur at the flank face, rake face and/or cutting edge. There are several factors affecting the tool wear. These include, but are not limited to, drilling parameters and environments/conditions, drill/tool materials and geometries, FRP composite compositions and machining techniques. Hence this chapter focuses on drilling parameters, tool materials and geometries, drilling environments, types of tool wear, mechanisms of tool wear and methods of measurement of wear, effects of wear on machining of composite materials and preventive measures against rapid drill wear. Conclusively, some future perspectives or outlooks concerning the use of drill tools and their associated wears are elucidated, especially with the advancement in science and technologyItem Open Access A critical review of 3D printing and digital manufacturing in construction engineering(Emerald, 2022-02-15) Ali, Md. Hazrat; Issayev, Gani; Shehab, Essam; Sarfraz, ShoaibPurpose In recent years, 3D printing technologies have been widely used in the construction industry. 3D printing in construction is very attractive because of its capability of process automation and the possibility of saving labor, waste materials, construction time and hazardous procedures for humans. Significant researches were conducted to identify the performance of the materials, while some researches focused on the development of novel techniques and methods, such as building information modeling. This paper aims to provide a detailed overview of the state-of-the-art of currently used 3D printing technologies in the construction areas and global acceptance in its applications. Design/methodology/approach The working principle of additive manufacturing in construction engineering (CE) is presented in terms of structural design, materials used and theoretical background of the leading technologies that are used to construct buildings and structures as well as their distinctive features. Findings The trends of 3D printing processes in CE are very promising, as well as the development of novel materials, will gain further momentum. The findings also indicate that the digital twin (DT) in construction technology would bring the industry a step forward toward achieving the goal of Industry 5.0. Originality/value This review highlights the prospects of digital manufacturing and the DT in construction engineering. It also indicates the future research direction of 3D printing in various constriction sectors.Item Open Access Effect of different dielectrics on material removal rate, electrode wear rate and microstructures in EDM(Elsevier, 2017-05-09) Niamat, Misbah; Sarfraz, Shoaib; Aziz, Haris; Jahanzaib, Mirza; Shehab, Essam; Ahmad, Wasim; Hussain, SalmanDiesinker electric discharge machining is widely used non-conventional technique for making high precision and complex shaped parts. Dielectrics and electrical parameters were considered as the main factors for EDM performance. In this paper, the effects of pulse-on-time (μs) and current (ampere) were evaluated for performance measures using kerosene and water as dielectrics. A comparison was performed for both dielectrics in terms of material removal rate (mm3/min), electrode wear rate (mm3/min), and microstructures. Aluminum 6061 T6 alloy was used as material for this research due to its extensive use in aerospace and automotive industries. Experiments were designed using Taguchi L9 orthogonal array (OA). Time series graphs were plotted to compare material removal rate and electrode wear rate. Microstructures were taken by scanning electron microscope to analyze the surface produced in terms of cracks, globules and micro-holes. Higher material removal rate and lower electrode wear were achieved with kerosene dielectric. The novelty of this research work, apart from its practical application, is that Aluminum 6061 T6 alloy is used as work material to compare the performance of dielectrics (kerosene and distilled water). Paper presented at: Complex Systems Engineering and Development Proceedings of the 27th CIRP Design Conference Cranfield University, UK 10th – 12th May 2017.Item Open Access Energy benchmarking of manufacturing processes in foundation industries(Elsevier, 2024-01-12) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark; Salonitis, KonstantinosBenchmarking energy consumption and utilisation has become a crucial tool for the manufacturing sector in the drive towards sustainability. However, incorporating industrial perspectives into benchmarking efforts is necessary to identify effective and relevant metrics. This study aims to evaluate the metrics for benchmarking energy utilisation within the foundation industries by deploying two surveys while incorporating the views of industry and subject matter experts. The study also involved conducting interviews with metal foundries to investigate the energy consumption of their processes and their metrics utilisation. The findings indicate the need for an accurate and reliable method to extract values for energy benchmarking of manufacturing processes. Proper procedures must be in place to ensure the data is collected consistently and uniformly across different processes and organisations. The deployment of effective and relevant metrics through industrial prospection will help ensure the benchmarking process is meaningful, actionable and supports the goal of a more sustainable future.Item Open Access Environmental assessment of recycling carbon fibre-reinforced composites: current challenges and future opportunities(Springer, 2022-11-19) Meiirbekov, Arshyn; Amantayeva, Akniyet; Tokbolat, Serik; Suleimen, Aidar; Sarfraz, Shoaib; Shehab, EssamThe increasing application of carbon fiber reinforced polymer composites (CFRP) across different industries raises environmental concerns. It requires focusing on the end-of-life phase of the product/material. The environmental benefits of CFRP recycling over conventional ways of treatment are apparent. However, estimating the environmental impacts is followed up with various challenges. In this study, the aspects of environmental assessment of CFRP recycling and their respective challenges are examined. CFRP recycling methods such as mechanical treatment, pyrolysis, fluidized bed process, and solvolysis have been previously studied in the context of energy and environmental assessment under the Life-Cycle-Assessment (LCA) framework. This study focused on the identification of challenges associated with variability of applied methods used, comparability, scaling results, data, uncertainty, and resource-demanding process of LCA. Recommendations on overcoming the identified challenges are provided and discussed.Item Open Access Evaluation of productivity and operating cost of laser drilling process – a case study(IOS Press, 2018-09-13) Sarfraz, Shoaib; Shehab, Essam; Salonitis, KonstantinosLaser drilling is a non-conventional machining process which is widely used in automotive, electronics and aerospace sectors to produce holes in diverse range of materials. Different types of lasers and methods are available to produce various hole geometries. Big number of researchers have examined several ways to enhance the performance of this process by investigating different process parameters and drilling methods, that seek improvement of the drilled hole quality. Whereas, productivity and operating cost are also important factors which need to be evaluated along with drilled hole quality. Reducing the drilling time can improve productivity and the selection of a suitable laser can save operating cost which will benefit laser processing industries in this global competitive environment. A case study was performed using different lasers for single pulse and percussion drilling. A significant improvement in productivity was observed with the use of a high power laser that is subject to high operating cost.Item Embargo Evaluation of the influence of dissolved nitrates on corrosion behaviour of ship structural steel exposed to seawater environment(Elsevier, 2024-02-29) Abbas, Muntazir; Rizvi, Syed Haider Mehdi; Sarfraz, Shoaib; Raza, Asif; Khan, Asif; Loya, Adil; Najib, AntashCorrosion rates in marine structural steels differ significantly with the varying compositions of seawater particularly near harbours or coastal regions primarily due to the presence of untreated chemically active species from various sources. The reviewed literature reports accelerated steel corrosion losses in coastal seawater exposure conditions, which has widely been attributed to the presence of aggressive chemical compounds e.g., dissolved inorganic nitrogenous (DINs) compounds, sulphur containing compounds, in combination with various other environmental factors and their interdependent complex relationships. This paper aims to investigate the influence of nitrates, a DIN compound, on the corrosion behaviour of a low carbon ship structural steel, by exposing surface the cleaned coupons to an artificial seawater solution in a controlled laboratory environment. The uniform and localised corrosion damages were measured on steel coupons by using the standard weight loss and the dimensional metrology methods. A significant increase in corrosion losses was observed on coupons exposed to the nitrate-added artificial seawater than those exposed to similar seawater compositions with no additional nitrate content. Elemental compositions of corrosion deposits and corrosion morphologies investigated using various analytical tools such as SEM, EDS and Raman scattering techniques have shown different types of corrosion products in both exposure conditions.Item Open Access Experimental investigation of productivity, specific energy consumption, and hole quality in single-pulse, percussion, and trepanning drilling of IN 718 superalloy(MDPI, 2019-12-04) Sarfraz, Shoaib; Shehab, Essam; Salonitis, Konstantinos; Suder, WojciechLaser drilling is a high-speed process that is used to produce high aspect ratio holes of various sizes for critical applications, such as cooling holes in aero-engine and gas turbine components. Hole quality is always a major concern during the laser drilling process. Apart from hole quality, cost and productivity are also the key considerations for high-value manufacturing industries. Taking into account the significance of improving material removal quantity, energy efficiency, and product quality, this study is performed in the form of an experimental investigation and multi-objective optimisation for three different laser drilling processes (single-pulse, percussion, and trepanning). A Quasi-CW fibre laser was used to produce holes in a 1 mm thick IN 718 superalloy. The impacts of significant process parameters on the material removal rate (MRR), specific energy consumption (SEC), and hole taper have been discussed based on the results collected through an experimental matrix that was designed using the Taguchi method. The novelty of this work focuses on evaluating and comparing the performance of laser drilling methods in relation to MRR, SEC, and hole quality altogether. Comparative analysis revealed single-pulse drilling as the best option for MRR and SEC as the MRR value reduces with percussion and trepanning by 99.70% and 99.87% respectively; similarly, percussion resulted in 14.20% higher SEC value while trepanning yielded a six-folds increase in SEC as compared to single-pulse drilling. Trepanning, on the other hand, outperformed the rest of the drilling processes with 71.96% better hole quality. Moreover, optimum values of parameters simultaneously minimising SEC and hole taper and maximising MRR are determined using multi-objective optimisation.Item Open Access An experimental investigation on Cryo-LN2 turning of hardened steel: a sustainability assessment(IOS Press, 2019-09-12) Khan, Aqib Mashood; Jamil, Muhammad; Hao, Xiuqing; Ning, He; Sarfraz, Shoaib; Goher, Kamran; Shehab, EssamTo achieve an excellent workpiece surface quality and long tool life in machining of hardened steel is an inordinate challenge. Recently, conventional flood cooling assisted machining processes are used to address this problem. However, such proposed processes have adverse effects on the environment as well as on the machine shop worker’s health. Hence, in this study, the effects of traditionally used flood cooling and sustainable Cryo-LN2 techniques on the six machining indices, such as surface roughness, cutting power, energy consumption, tool life, tool wear, and productivity in the external turning of AISI-52100 have been investigated. Comparative results showed that Cryo-LN2 technique outperformed flood cooling for all measured indices. The Cryo-LN2 assisted turning process yielded 18% less energy consumption and 66% more productivity. The findings of the current study encourage metal processing industries to use such type of sustainable techniques in the machine shop.Item Open Access Identification of the right environmental KPIs for manufacturing operations: towards a continuous sustainability framework(MDPI, 2022-11-01) Sherif, Ziyad; Sarfraz, Shoaib; Jolly, Mark; Salonitis, KonstantinosSustainable manufacturing has grown into a major subject of discussion between individuals and organisations around the world. This is attributed to the recognition of the urgency in advancing sustainable manufacturing due to the diminishing non-renewable resources, stricter regulations related to environmental impacts and the increasing consumer preference for environmental-friendly products. However, manufacturing companies have been confronted with a decision on which KPIs to select for appraising their processes, and how they should interpret these KPIs in transforming their processes towards a sustainable future. This paper presents a structured framework for the manufacturing industries to identify the right environmental KPIs. It includes building a database for environmental KPIs, categorising, ranking, and composing a final KPI set for specified targets. The developed method allows for the selection of the most effective KPI in representing a specified target as well as identifying unmonitored environmental aspects. The framework has been corroborated by subject matter and industry experts in which the potential benefits have been verified.Item Open Access An integrated analysis of productivity, hole quality and cost estimation of single-pulse laser drilling process(Sage, 2020-11-03) Sarfraz, Shoaib; Shehab, Essam; Salonitis, Konstantinos; Suder, Wojciech; Niamat, Misbah; Jamil, MuhammadLaser drilling is a well-established manufacturing process utilised to produce holes in various aeroengine components. This research presents an experimental investigation on the effects of laser drilling process parameters on productivity (material removal rate), hole quality (hole taper) and drilling cost. Single-pulse drilling was employed to drill a thin-walled Inconel 718 superalloy plate of 1mm thickness using pulsed Nd:YAG laser. The experiments were designed using Box-Behnken statistical approach to investigate the impacts of pulse energy, pulse duration, gas pressure and gas flow rate on the selected responses. Multi-objective optimisation was performed using response surface methodology (RSM) based grey rational analysis (GRA) to identify optimal drilling conditions aiming to maximise the MRR and minimise hole taper and drilling cost. The optimal combination of drilling parameters was found as pulse energy of 20 J, pulse duration of 6 ms, gas pressure of 100 psi and gas flow rate of 40 mm3/s. A detailed cost analysis identified labour cost, gas consumption and machine costs as the major cost elements of the laser drilling processItem Open Access Internal cracks and non-metallic inclusions as root causes of casting failure in sugar mill roller shafts(MDPI, 2019-08-03) Jamil, Muhammad; Khan, Aqib Mashood; Hegab, Hussien; Sarfraz, Shoaib; Sharma, Neeraj; Mia, Mozammel; Gupta, Munish Kumar; Zhao, GuLong; Moustabchir, H.; Pruncu, Catalin I.The sugar mill roller shaft is one of the critical parts of the sugar industry. It requires careful manufacturing and testing in order to meet the stringent specification when it is used for applications under continuous fatigue and wear environments. For heavy industry, the manufacturing of such heavy parts (>600 mm diameter) is a challenge, owing to ease of occurrence of surface/subsurface cracks and inclusions that lead to the rejection of the final product. Therefore, the identification and continuous reduction of defects are inevitable tasks. If the defect activity is controlled, this offers the possibility to extend the component (sugar mill roller) life cycle and resistance to failure. The current study aims to explore the benefits of using ultrasonic testing (UT) to avoid the rejection of the shaft in heavy industry. This study performed a rigorous evaluation of defects through destructive and nondestructive quality checks in order to detect the causes and effects of rejection. The results gathered in this study depict macro-surface cracks and sub-surface microcracks. The results also found alumina and oxide type non-metallic inclusions, which led to surface/subsurface cracks and ultimately the rejection of the mill roller shaft. A root cause analysis (RCA) approach highlighted the refractory lining, the hot-top of the furnace and the ladle as significant causes of inclusions. The low-quality flux and refractory lining material of the furnace and the hot-top, which were possible causes of rejection, were replaced by standard materials with better quality, applied by their standardized procedure, to prevent this problem in future production. The feedback statistics, evaluated over more than one year, indicated that the rejection rate was reduced for defective production by up to 7.6%.Item Open Access Investigation of electric discharge machining parameters to minimize surface roughness(Pakistan Association for the Advancement of Science, 2016-09-30) Sarosh, M.; Jahanzaib, Mirza; Mumtaz, J.; Sarfraz, Shoaib: Surface roughness during electrical discharge machining (EDM) was determined, in which material is removed by thermo-electric process due to the occurrence of successive discharge between workpiece and electrode. Box-Behnken design (BBD) involving four parameters discharge current (I), Pulse ON time (PON), Pulse OFF time (POFF) and Gap voltage, with three levels was employed to minimize the surface roughness. Other parameters such as Servo speed, Polarity and Die-electric pressure were kept constant throughout the machining. A copper electrode tool was used to machine the holes in AISI 1045 steel work piece. Mathematical models were developed using Response Surface Methodology (RSM), while Analysis of variance (ANOVA) was used to observe individual effect, interaction between parameters, and to check validity of models. Results revealed that pulse on time and discharge current were two main significant parameters that statistically affected surface roughness.Item Open Access Investigation of productivity, energy efficiency, quality and cost for laser drilling(Cranfield University, 2020-10) Sarfraz, Shoaib; Shehab, Essam; Salonitis, Konstantinos; Suder, WojciechLaser drilling is a high speed, non-contact advanced machining process and has proven to be an important industrial process for producing cooling holes in various aeroengine components; in particular high-pressure turbine blades, combustor liners and nozzle guide vanes. However, an increase in the number of cooling holes demands the need for effective utilisation of laser drilling process capability. Material removal rate (MRR), specific energy consumption (SEC), hole taper and the drilling cost are the basic performance indicators to meet this goal. Hence, this research aims to examine the laser drilling process in terms of the mentioned performance measures. Taking into account the significance of material removal quantity, energy efficiency, product quality and manufacturing cost, this study is performed in the form of an experimental investigation for three laser drilling processes, namely, single-pulse drilling, percussion and trepanning. Two different laser drilling setups were prepared to produce holes in Inconel 718 superalloy sheets using flashlamp-pumped Nd:YAG laser and Quasi-CW fibre laser. This research contributes to an evaluation of the influence of laser drilling process parameters on the MRR, SEC, hole quality and drilling cost. Moreover, the performance of laser drilling methods has been compared in relation to the selected performance measures. To further understand the significance of laser sources, the performance of laser drilling was compared for the mentioned drilling setups. This research also introduced a detailed cost analysis to explore the economic implications of the laser drilling process. In addition, optimal drilling conditions were determined aiming to maximise the MRR and minimise hole taper and drilling cost.Item Open Access Investigation of temperature in orthopaedic drilling using response surface methodology(Pakistan Association for the Advancement of Science, 2016-09-30) Jamil, Muhammad; Sarfraz, Shoaib; Jahanzaib, MirzaRise in temperature is inevitable in orthopaedic drilling. Massive research had been done in the field of orthopaedic drilling to investigate the effect of cutting conditions, bone related parameters, and drill bit geometric parameters on heat generation and minimum surrounding tissues injury. In present research, contradictory conclusions regarding the cutting conditions and drill bit geometric parameters were observed. Minimum temperature of 31°C was achieved at speed of 186 rpm, feed of 0.196 mm/rev, drill diameter of 3.85mm, and drill tip angle of 110°. Response Surface Methodology (RSM) was used to develop a mathematical model to predict the type of relationship between inputs and response. It was concluded that the most influencing parameter was drill diameter.Item Open Access Investigations on quality characteristics in gas tungsten arc welding process using artificial neural network integrated with genetic algorithm(Springer, 2021-03-06) Valle Tomaz, Italo do; Colaço, Fernando Henrique Gruber; Sarfraz, Shoaib; Pimenov, Danil Yu; Gupta, Munish Kumar; Pintaude, GiuseppeGas tungsten arc welding (GTAW) technology is widely used in industry and has advantages, including high precision, excellent welding quality, and low equipment cost. However, the inclusion of a large number of process parameters hinders its application on a wider scale. Therefore, there is a need to implement the prediction and optimization models that effectively enhance the process performance of the GTAW process in different applications. In this study, a five-factor five-level central composite design (CCD) matrix was used to conduct GTAW experiments. AISI 1020 steel blank was used as a substrate; UTP AF Ledurit 60 and UTP AF Ledurit 68 were used as the materials of two tubular wires. Further, an artificial neural network (ANN) was used to simulate the GTAW process and then combined with a genetic algorithm (GA) to determine welding parameters that can provide an optimal weld. In welding experiments, five different welding current levels, welding speed, distance to the nozzle, angle of movement, and frequency of the wire feed pulses were used. Using GA, optimal welding parameters were determined: welding current = 222 A, welding speed = 25 cm/min, nozzle deflection distance = 8 mm, travel angle = 25°, wire feed pulse frequency = 8 Hz. The determination coefficient (R2) and RMSE value of all response parameters are satisfactory, and the R2 of all the data remained higher than 0.65Item Open Access Multi-objective optimisation for minimum quantity lubrication assisted milling process based on hybrid response surface methodology and multi-objective genetic algorithm(Sage, 2019-04-22) Mumtaz, Jabir; Li, Zhang; Imran, Muhammad; Yue, Lei; Jahanzaib, Mirza; Sarfraz, Shoaib; Shehab, Essam; Ismail, Sikiru Oluwarotimi; Afzal, KaynatParametric modelling and optimisation play an important role in choosing the best or optimal cutting conditions and parameters during machining to achieve the desirable results. However, analysis of optimisation of minimum quantity lubrication–assisted milling process has not been addressed in detail. Minimum quantity lubrication method is very effective for cost reduction and promotes green machining. Hence, this article focuses on minimum quantity lubrication–assisted milling machining parameters on AISI 1045 material surface roughness and power consumption. A novel low-cost power measurement system is developed to measure the power consumption. A predictive mathematical model is developed for surface roughness and power consumption. The effects of minimum quantity lubrication and machining parameters are examined to determine the optimum conditions with minimum surface roughness and minimum power consumption. Empirical models are developed to predict surface roughness and power of machine tool effectively and accurately using response surface methodology and multi-objective optimisation genetic algorithm. Comparison of results obtained from response surface methodology and multi-objective optimisation genetic algorithm depict that both measured and predicted values have a close agreement. This model could be helpful to select the best combination of end-milling machining parameters to save power consumption and time, consequently, increasing both productivity and profitability.Item Open Access Multi-objective optimization of energy consumption and surface quality in nanofluid SQCL assisted face milling(MDPI, 2019-02-21) Khan, Aqib Mashood; Jamil, Muhammad; Salonitis, Konstantinos; Sarfraz, Shoaib; Zhao, Wei; He, Ning; Mia, Mozammel; Zhao, GuoLongConsidering the significance of improving the energy efficiency, surface quality and material removal quantity of machining processes, the present study is conducted in the form of an experimental investigation and a multi-objective optimization. The experiments were conducted by face milling AISI 1045 steel on a Computer Numerical Controlled (CNC) milling machine using a carbide cutting tool. The Cu-nano-fluid, dispersed in distilled water, was impinged in small quantity cooling lubrication (SQCL) spray applied to the cutting zone. The data of surface roughness and active cutting energy were measured while the material removal rate was calculated. A multi-objective optimization was performed by the integration of the Taguchi method, Grey Relational Analysis (GRA), and the Non-Dominated Sorting Genetic Algorithm (NSGA-II). The optimum results calculated were a cutting speed of 1200 rev/min, a feed rate of 320 mm/min, a depth of cut of 0.5 mm, and a width of cut of 15 mm. It was also endowed with a 20.7% reduction in energy consumption. Furthermore, the use of SQCL promoted sustainable manufacturing. The novelty of the work is in reducing energy consumption under nano fluid assisted machining while paying adequate attention to material removal quantity and the product’s surface quality.