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Proceedings of The Institution of Mechanical Engineers, Part B - Journal of Engineering Manufacture-1999-Brinksmeier-769-78
Proceedings of The Institution of Mechanical Engineers, Part B - Journal of Engineering Manufacture-1999-Brinksmeier-769-78
Abstract: Coolant lubricants are recognized as undesirable factors in metal cutting, especially in
machining advanced and difcult-to-cut materials. For both economic and ecological reasons, as
well as because of increasing legislation, efforts are being made to reduce the use of coolants. On
account of this, the introduction of dry machining and minimum quantity lubrication (MQL)
techniques in machining processes is increasing. The results of the investigations carried out give an
overview of the possibilities for inuencing the machining of advanced materials, e.g. titanium alloys
and extreme low-sulphur steels. The research topics focus on cutting tool performance and wear
mechanisms at high cutting speeds while using different lubricants and cooling supply strategies. The
investigations and verication experiments contribute to increasing process stability and tool life,
improvement of machined surface nish and avoidance of tensile residual stresses.
Keywords: dry machining, minimum quantity lubrication (MQL), hardened steels, titanium alloys,
low-sulphur steels
NOTATION Fe iron
FeS iron sulphide
ae back engagement of the cutting tool (mm) h thickness of cut (mm)
ap working engagement of the cutting tool h% chip thickness (mm)
(mm) HB Brinell hardness
Al aluminium HC hard metal
Al2O3 aluminium oxide HRB Rockwell hardness, ball
C carbon HRC Rockwell hardness, cone
CL cooling lubricant HSS high-speed steel
Co cobalt HW coated hard metal
Cr chromium l drilling depth (mm)
Cu copper Mc cutting torque (N/m)
d diameter of hole (mm) Mn manganese
D diameter of drill (mm) MnS manganese sulphide
DF tool diameter Mo molybdenum
DH double stroke MQL minimum quantity cooling lubrication
E energy (J) n spindle speed (min1)
f feed (mm) N nitrogen
fz feed per tooth (mm) Nb niobium
F force (N) Ni nickel
Fc cutting force (N) P phosphorus
Ff feed force (N) rm tool nose corner radius (mm)
Fp back force (N) Ra arithmetical mean deviation of the prole
(mm)
The MS was recei6ed on 5 No6ember 1998 and was accepted for Rz ten point height of irregularities (mm)
publication on 3 March 1999. S sulphur
*Corresponding author: Main Department of Manufacturing Technolo-
gies, Foundation Institute for Material Science (IWT), Badgasteiner SEM scanning electron microscope
Strasse 3, D 28359 Bremen, Germany. Si silicon
B08498 IMechE 1999 Proc Instn Mech Engrs Vol 213 Part B
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770 E BRINKSMEIER, A WALTER, R JANSSEN AND P DIERSEN
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ASPECTS OF COOLING LUBRICATION REDUCTION IN MACHINING ADVANCED MATERIALS 771
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772 E BRINKSMEIER, A WALTER, R JANSSEN AND P DIERSEN
tempered to 29 HRC for 2 h at 610 C. A vitried tion by the small oil content within the emulsion is
bonded carborundum wheel, characterized by mean great enough. On the other hand, in MQL with ester
bonding hardness and porosity, was chosen because the oil, at least a sufcient lubrication can be achieved. The
lower density of the structure should minimize the SEM micrographs of grinding chips demonstrate that
loading of the grinding wheel. Moreover, it was ex- the reduction in cooling lubricants results in increasing
pected that a greater porosity would lead to better chip amounts of heat entering the chips (Fig. 5).
removal as well as to an optimized lubricant supply to If the contact zone is ooded, relatively long chips of
the contact zone. differing dimensions and shapes are generated. In MQL
When grinding the tempered steel, signicantly lower and towards dry grinding, more and more fragmented
process forces were needed compared with the forces to chips characterized by a higher deformation are pro-
grinding the hardened material, because the deforma- duced. Especially in dry grinding of the soft material,
tion resistance was lower and also because of the many spherical chips as well as molten and solidied
inuence of the wheel specication. It must be pointed particles with a dendritic structure are formed. It can be
out that, even at higher specic material removal rates, gathered from this observation that the heat ux in the
no thermal damage to the workpiece was detectable. grinding of unhardened steels using a vitried bonded
The normal forces for different coolants and coolant wheel mainly occurs via the chips if the cooling supply
supply techniques vary only slightly (Fig. 3). Flooding is reduced. Thermal impacts on the workpiece are
coolant supply and MQL by an ester oil lead to lower thereby avoided. Furthermore, it must be taken into
forces than dry grinding with MQL by an emulsion. account that the tempered structure is less sensitive to
Nevertheless, the differences, especially for mean mate- high-temperature variations compared with the hard-
rial removal rates, seem to be negligible. ened structure [8].
The effect of cooling on machining becomes more
2.2 Machining of low-sulphur steels
evident when looking at the workpiece roughness (Fig.
4). MQL by ester oil and ooding coolant supply The relationship between workpiece material properties
provide the best surface quality. If an emulsion is used and tool wear has to be known to improve the eco-
for MQL instead of an ester oil, the roughness will nomic aspects of the machining of steels. The machin-
become higher than in dry grinding [1]. Obviously, in ability of steels is highly inuenced by workpiece
MQL with emulsion neither the cooling nor the lubrica- material properties because of [9]:
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ASPECTS OF COOLING LUBRICATION REDUCTION IN MACHINING ADVANCED MATERIALS 773
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774 E BRINKSMEIER, A WALTER, R JANSSEN AND P DIERSEN
their decrease when MQL is applied are signicantly In addition, the effect of cooling supply strategies on
smaller. This decrease in forces was accompanied by an drilling with HSS drills was also investigated. Drilling
improvement in the surface quality and tool life by 20 of low-sulphur steels is a particularly difcult process
per cent. A possible reason for this result is that the because the chips have to be transported out of the
lubrication effect when machining materials with a generated hole. The effect of cooling lubrication on drill
higher sulphur content provided by manganese sul- wear is shown in Fig. 8. It illustrates the possible
phides can be replaced by MQL. number of holes drilled before the maximum width of
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ASPECTS OF COOLING LUBRICATION REDUCTION IN MACHINING ADVANCED MATERIALS 775
B08498 IMechE 1999 Proc Instn Mech Engrs Vol 213 Part B
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776 E BRINKSMEIER, A WALTER, R JANSSEN AND P DIERSEN
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ASPECTS OF COOLING LUBRICATION REDUCTION IN MACHINING ADVANCED MATERIALS 777
In addition, the effects of different cooling supply tity lubrication is a suitable alternative for economically
strategies for the use of high-speed steel tools were and environmentally compatible production. It com-
investigated. Under these conditions the improvement bines the functionality of cooling lubrication with an
with MQL is clearly better. The effect is nearly the extremely low consumption of lubricant and therefore
same as for the use of overow lubrication. For the use has the potential to close the gap between overow
of HSS tools, it can be established that the tendency of lubrication and dry machining. This article gives exam-
the titanium to pressure weld to the tool ank can be ples of successful reduction in the amount of coolant
almost completely avoided by the use of oil mist lubri- used in machining. In conclusion, it can be stated that
cation. These results are applicable for all investigated it is essential to select appropriate machining parame-
MQL lubricants. The slight differences between lubri- ters and suitable tools in order to utilize this potential.
cants with and without additives are presented in Fig. Therefore, a detailed analysis of the entire cutting pro-
11. cess, consisting of workpiece, tool, coolant and machine
Products with high amounts of antiwear additives tool, is necessary.
lead to further increase in tool life. In this case it turned
out that high-additive products lead to better results
compared with emulsions in overow conditions. The REFERENCES
lower tool wear also leads to an improvement in the
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3 CONCLUSIONS
2 Zielasko, W. Werkzeugstandzeiten bei unterschiedlichen
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quality and accuracy in metalworking processes. In 3 Tonshoff, H. K. and Brunner, G. Minimalmengen-
recent years, the disadvantages of cooling lubricants Kuhlschmierung bei Schleifprozessen. Maschinenmarkt,
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gies to reduce the amount of cooling lubricants used in malmengen-Kuhlschmierung und Trockenbearbeitung. In
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perience lead to the conclusion that complete avoidance
schmierung und Trockenbearbeitung beim Schleifen.
of cooling lubrication in metalworking will not be Praxis-Forum Tagung Fertigungstechnik, 1996 (Technik +
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The investigations have shown that the minimum quan- Maschinenmarkt, 1995, 101.
B08498 IMechE 1999 Proc Instn Mech Engrs Vol 213 Part B
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778 E BRINKSMEIER, A WALTER, R JANSSEN AND P DIERSEN
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Proc Instn Mech Engrs Vol 213 Part B B08498 IMechE 1999
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