Papers by Keyword: Cutting Fluid

Abstract: Geared components increasingly require higher torque density, driving the use of high-strength steels and necessitating stable machining processes, particularly in small and medium-sized enterprises that rely on cutting fluids. This study evaluates the performance potential of various cutting fluids in gear hobbing using a fly-cutting analogy test setup, which enables controlled and reproducible analysis of wear mechanisms of a single hob tooth. Water-based and oil-based cutting fluids, different tool substrate materials (PM-HSS, MC90, and tungsten carbide), and workpiece steels of different strength levels were systematically investigated. The results show that PM-HSS is unsuitable for machining the highest-strength material. Dry machining improved tool life, whereas the application of cutting fluids led to increased tool wear.

Abstract: Currently, functional tests and property tests are used to evaluate cutting fluid [1]. However, the problem is that the results obtained from above tests do not always match with each other because the insert tip is under extreme pressure and high temperature in actual machining. Therefore, a new cutting fluid evaluation method based on actual machining is needed. End face cutting in lathe machining is cutting workpiece from outside to center. In this study, rotation speed was fixed. In other words, cutting speed varies with the radius of workpieces and it is considered possible to clarify the effectiveness of cutting fluid at each cutting speed in a single cut.The performance of the cutting fluid was evaluated based on acceleration of cutting tool and surface roughness of workpiece. The following results were obtained. In steel materials, the acceleration of insoluble cutting oil was highest, and burnt insert tips were observed after the end face cutting. Insoluble cutting oil used in this study has a lower viscosity and a lower boiling point than mineral oils and esters. The highest acceleration of insoluble cutting oil is considered to be due to insufficient lubricating effect because of evaporation of it. No effect of insoluble cutting oil, mineral oils or esters was obtained on surface roughness. The acceleration of undiluted solution is higher than that of diluted solution and burnt insert tips were obtained. The cooling effect of undiluted solution is low because of less water. The highest acceleration of undiluted solutions is considered to be due to insufficient lubricating effect because of evaporation of it. In A5056, surface roughness of the diluted solution was higher at low cutting speed due to lack of lubricating effect. Differences in acceleration, surface roughness and insert tip were observed for each oil type, indicating the possibility of evaluating cutting fluid performance using the method proposed in this study.

Abstract: This study focuses on the effect of cutting fluid on sample surface integrity and tool wear in milling additively manufactured Inconel 738LC. Sample surface integrity and tool wear characterization was undertaken using scanning electron microscopy, backscatter electron microscopy, energy dispersive spectroscopy, laser scanning confocal microscopy, ultra-depth of field digital microscope system and digital display hardness tester. Compared with dry milling, wet milling not only provides an entirely different result on surface morphology, but also shows less surface plastic deformation, and smaller surface roughness. In addition, the tool wear mechanisms of wet milling are found to be different compared to dry milling.

Abstract: The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.

Abstract: Metal cutting processes such as machining or abrasive processes are related to the production of relatively large amounts of heat, as a result of the intense contact of workpiece and cutting tool. For that reason, it is often necessary to employ a cooling fluid in order to alleviate the intense and usually undesired heat-induced effects on the workpiece. Due to the cost and environmental concerns regarding cutting fluids, the heat absorbing efficiency and quantity of cutting fluids employed is always a concern. In the present work, the effect of cutting fluid type in the temperature profile of the workpiece during grinding is investigated and useful conclusions are drawn, concerning the efficiency of nanofluids as cutting fluids.

Abstract: In this study, the difference of finished surface roughness and feed mark shape in lubricity of the cutting fluids were investigated in turning SUS440C. In the cutting speed of 20m/min, the oil having excellent oiliness caused the smallest finished surface roughness among the tested cutting fluids at the feed rate of 0.1mm/rev, while, the oil having high extreme pressure property was best at the feed rate of 0.2mm/rev. The feed marks were hardly recognized at any conditions. In the cutting speed more than 20m/min, the finished surface roughness in any lubricant conditions showed almost the same or slightly larger compared with that in dry conditions. The feed marks were recognized, and the transcription of cutting edges shape under wet conditions trended to be the same or worse than dry conditions.

Abstract: Cutting fluid is commonly used during metal cutting process for cooling and lubrication. Fluid types are generally classified into mineral or fatty oils and water miscible oils. In Japan, the former is called water-insoluble coolants, and the latter is called water-soluble coolants. Water-insoluble coolants are specified as dangerous material by the Japanese law due to its flammability. Therefore, the water-insoluble coolants are not appropriate for unmanned operation of machine tools. Therefore, the usage rate of water-soluble coolants is increasing. Water soluble coolants are diluted with a water by several ten times. The waste management of the water-soluble coolant become important for environment-conscious green manufacturing. We have been developing a recycling system for water-soluble coolants. In the recycle system, water is extracted from the waste coolant and the water is then reutilized as a diluent of a new coolant. We have developed various types of chemical or bio-chemical water recovery methods for recycling systems. We found a commercially available amine-free water-soluble coolant is suitable for the recycling system. The processing time, processing cost, and the biochemical and chemical oxygen demand of the extracted water are improved by the amine-free water soluble coolant compared with a conventional amine-containing coolant. However, its corrosion inhibition performance was poor in general machining applications. Our cooperative company developed a prototype of a corrosion-inhibition-improved amine-free water-soluble cutting coolant. The prototype coolant showed a good stability and cooling and lubricating performances, and its recyclability was as good as that of conventional amine-free coolants. In this study, we focused on repeated recycling of the prototype coolant. We repeatedly applied the water recycling process to the recycled coolant. The recyclability of the prototype coolant was not affected by repeated recycling; however, process residues increased with the number of recycles, and a deterioration was noticed in the corrosion-inhibition performance of the coolant diluted with recycled water.

Abstract: The selection of optimum machining parameters plays a significant role for the quality characteristics of products and its costs for grinding. This study describes the optimization of the grinding process for an optimal parametric combination to yield a surface roughness using the Taguchi method. An orthogonal array and analysis of variance are employed to investigate the effects of cutting environment (A), depth of cut (B) and feed rate (C) on the surface roughness characteristics of mold steels. Confirmation experiments were conducted to verify the optimal testing parameters. The experimental results indicated that the surface finish decreased with cutting-fluid and depth of cut, but decreased with increasing feed rate. It is revealed that the cutting fluid environment had highest physical as well as statistical influence on the surface roughness (71.38%), followed by depth of cut (25.54%), but the least effect was exhibited by feed rate (1.62%).

Abstract: In this paper an experiment was carried out to examine the magnitude of differences among cutting fluids and their influence on lathe power consumption during machining. It was discovered that there is no universal cutting fluid. An attempt was made to study the possibility of Artificial Neural Network to model the behavior function for all cutting fluids. This could be used as a foundation for later database building where it would be possible to predict how certain cutting fluid will behave in a specific machining parameter combination.

Abstract: The concern for environmental problems has been increasing rapidly in recent years. Water-soluble coolants are widely used in machining processes. To reduce management costs and the environmental load of water-soluble coolants, the authors studied a recycling system for water-soluble coolants. With this recycling system, water is extracted from a waste coolant by chemical or biochemical treatment; the recovered water is re-utilized as a diluent for a new coolant. Coolant recyclability depends on the coolant type. Most water-soluble coolants contain alkanolamines for corrosion inhibition and maintenance of putrefaction prevention. However, alkanolamines are difficult to eliminate from water-soluble coolants by chemical and physical waste treatment processes. Some amine-free, water-soluble coolants have been developed and are commercially available. The reduction of environmental load in the treatment of waste coolants is anticipated for amine-free coolants. We applied the recycling process to a commercially available amine-free, water-soluble coolant. The amine-free coolant showed good recyclability and lubricating performance. However, the corrosion inhibition performance of the coolant was inadequate for use in general machining. Recently, our cooperative company developed a prototype amine-free, water-soluble coolant with improved corrosion inhibition. In this study, we experimentally examined the recyclability and performance stability of this newly developed coolant. The experimental results showed that the new amine-free coolant has good corrosion inhibition equivalent to conventional amine-containing coolants. In addition, the recyclability, stability, and cooling and lubricating performance of the coolant are equal to conventional amine-free coolants. The amine-free, water-soluble coolant with improved corrosion inhibition has the advantage that it can be used in the recycling system for water-soluble coolants.