Choice of Lubricating and Cooling Action of Cutting Fluids by the Thermomechanical Model

Abstract:

The use of cutting fluids in turning can change thermomechanical loading of cutting tools. Currently, manufacturers provide a wide range of cutting fluids, which have different combinations of lubricating and cooling properties. Depending on cutting conditions, this combination can reduce tool wear in different degrees, and, in some cases, to even increase it. Therefore, an effective choice of cutting fluids requires a considerable amount of experiments, which requires cost and time. To solve this problem in the software SIMULIA/Abaqus Explicit 6.10 was developed thermomechanical model of the turning process by cutting tools with PVD-coating, which allows simulating the effect of any combination of cooling and lubricating action. An Arbitrary Lagrangian-Eulerian formulation method was used in the modeling. Under the lubricating and cooling action is understood the final result of interaction of cutting fluids with the cutting zone. Modeling of lubricating action of cutting fluid is performed by introducing into the model corresponding average coefficient of friction in the contact zone of cutting tool, worked material and cutting fluid. Modeling of cooling action of cutting fluids is implemented through the introduction of the heat transfer coefficient, calculated on the basis of cutting conditions and thermo-physical properties of cutting fluids. As an example, turning of austenitic stainless steel X10CrNiTi18 by carbide cutting insert with TiN-coating for a predetermined cutting condition was examined. A selection of cutting fluids of the proposed range, formulations of which have different combinations of cooling and lubricating properties ("Unizor-M", "Ferrobetol-M", "EkoEM-1", "STARCUT E9", "SAFECUT M120") was accomplished through the simulation model and the calculated data contact stresses. Experimental studies have confirmed the validity of this choice by comparing the rate of flank tool wear in the using different cutting fluids. The rate of wear was determined by surface micrographs of flank tool. An application of the recommended cutting fluid "SAFECUT M120" has reduced wear by 4 times as compared with the application of the "Ferrobetol-M", the use of which has shown the highest wear. The model developed can be used for selecting a predetermined range of cutting fluids, in determining the optimal combination of lubricating and cooling actions for establishing the required characteristics of cutting fluid or in developing new formulations of cutting fluids.

• Periodical: Advanced Materials Research (Volume 1036)
• Pages: 405-410
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.1036.405
• Online since: October 2014
• Authors: Alexander Mikhaylov, Elena Sydorova*, Ilya Navka
• Keywords: Abaqus Explicit, Cutting Fluids, PVD Coating, Simulation, Tool Wear, Turning

References

[1] O. Pantalé, Modélisation et simulation tridimensionnelles de la coupe des métaux, Ph.D. thesis, Université de Bordeaux I (1996).

[2] Приготовление и применение рабочей смазочно-охлаждающей жидкости (СОЖ) из концентрата СОЖ, «УНИЗОР-М»: технологическая инструкция, ООО «БАРКОР» (2005).

[3] Приготовление и применение рабочей эмульсии (смазочно-охлаждающей жидкости) из концентрата эмульсола «ФЕРРОБЕТОЛ-М», ООО «БАРКОР» (2005).

[4] Приготовление и применение рабочей эмульсии из концентрата смазочно-охлаждающей жидкости «ЭкоЭМ-1», ООО «БАРКОР» (2008).

[5] STARCUT E9: Водорастворимая СОЖ для металлообработки, Unil Lubricants.

[6] SAFECUT M120: Биостабильная полусинтетическая жидкость для обработки металлов, Unil Lubricants.

[7] A. Mikhailov, E. Sydorova, S. Selivra. Functional-oriented approach for analysis of physical-mechanical processes in the cutting zone, International Journal of Modern Manufacturing Technologies. Vol. 4 No1 (2012) 85–90.

[8] K. -D. Bouzakis, G. Skordaris, S. Gerardis, G. Katirtzoglou, S. Makrimallakis, M. Pappa, E. LilI and R. M'Saoubi, Ambient and elevated temperature properties of TiN, TiAlN and TiSiN PVD films and their impact on the cutting performance of coated carbide tools, Surface & Coatings Technology. 204 (2009).

DOI: 10.1016/j.surfcoat.2009.07.001

[9] Caracteristics of carbide grade, Professional grade carbide cutting tools DJET. Information o http: /www. dijetusa. com/products/dijet-carbide-grades/cg-carbide-grade-characteristics. pdf.

[10] Марочник сталей и сплавов. Information on http: /www. splav. kharkov. com/mat_start. php.

[11] F. Kalay, Simulation numérique de l'usinage Application à l'aluminium AU4G (A2024-T351), Techniques de l'ingénieur : les bases documentaires techniques et scientifiques (2006).

DOI: 10.51257/a-v1-bm7002

[12] В.О. Залога, Розробка наукових основ підвищення ресурсу інструментів із керамічних та надтвердих матеріалів для переривчастого різання на основі імітаційного моделювання : Звіт про НДР (проміжний), СумДУ, Суми (2010).

[13] J. -L. Bacaria, Un modèle comportemental et transitoire pour la coupe des métaux, Ph.D. thesis, ENI de Tarbes (2001).

[14] T. Ozel, M. Sima, A.K. Srivastava and B. Kaftanoglu, Investigations on the effects of multi-layered coated inserts in machining Ti–6Al–4V alloy with experiments and finite element simulations, CIRP Annals - Manufacturing Technology. 59 (2010).

DOI: 10.1016/j.cirp.2010.03.055

[15] Энтелис С.Г., Берлинер Э.М., Годлевский В.А. и др., Смазочно-охлаждающие технологические средства для обработки металлов резанием: справочник, Машиностроение, Москва (1995).

[16] ISO 3685, Essais de durée de vie des outils de tournage à partie active unique, AFNOR (1993).

[17] И.С. Праведников, Физическая сущность критических температур резания, Электронный научный журнал «Нефтегазовое дело». Information on http: /www. ogbus. ru/authors/Pravednikov/Pravednikov_7. pdf.