18MEPK0 – METAL CUTTING

ENGINEERING
Course Outcomes
By the end of the course, student will be able to:
1. Explain the types and characteristics of tool materials,
cutting tools nomenclature and various tool angle
specification
2. Explain the Mechanics of the machining process
3. Examine the thermal aspects and cutting fluids
4. Examine the tool wear, tool life, machinability.
5. Determine the tool life and surface roughness of machined
surfaces
6. Optimize the machining cost by varying the cutting
parameters
18MEPK0 – METAL CUTTING
ENGINEERING

Chapter-3
Thermal aspects and
cutting fluids

Prof. M.Karthic, M.E

E-mail: mkmect@tce.edu

2
 Chapter-3
Thermal aspects and cutting
fluids
3.1 Introduction – Shear plane temperature control in
orthogonal cutting- 1
3.2 Experimental determination of tool temperature- 1
3.3 Benefits of using cutting fluids – methods of
applying cutting fluids– 2
3.4
Types of cutting fluids- 1
3.2 Experimental determination of tool
temperature-
Determination of temperature distribution on the tool
rake face of the cutting tool is very important for
estimating tool wear and tool life.

Several techniques have been used for accurate

determination of temperature at different points on the tool.
1. Photosensitive paints
2. Tool-workpiece as a thermocouple
3. Tiny thermocouple – embedded in tool
4. Infrared photographic technique.
3.2 Experimental determination of tool
temperature-
Thermocouple – Tool and workpiece
3.2 Experimental determination of tool
temperature-
Thermocouple – Tool and workpiece
3.2 Experimental determination of tool
temperature-
Infrared photographic technique.
3.3 Cutting Fluids
 3.3 Cutting Fluids
THE PRIMARY FUNCTIONS OF CUTTING
FLUIDS IN MACHINING ARE…

1. Lubricating the cutting process at low cutting speed

2. Cooling the work piece at high cutting speed.
3. Flushing away chips from the cutting zone.
 3.3 Cutting Fluids
THE SECONDARY FUNCTIONS INCLUDE OF
CUTTING FLUIDS IN MACHINING ARE…

1. Corrosion protection of the machined surface

2. Enabling part handling by cooling the hot surface
 3.3 Cutting Fluids
PROPERTIES OF CUTTING FLUID
• It should posses good lubricating properties to reduce the
frictional force
• High heat conductivity/ absorption capacity.
• It should be non-toxic.
• It should be chemically inactive.
• It should not very easily flammable.(High flash point)
• It should be stable in use and storage.
• Harmless to health of workers
• No bad smell
 3.3 Cutting Fluids
Types of Cutting Fluids

4 Categories

1. Straight oils
2. Soluble oils
3. Synthetic fluids
4. Semi-synthetic fluids
 3.3 Cutting Fluids
Types of Cutting Fluids
Straight Oils
• Straight Oils, also referred to as neat oils, are petroleum or vegetable
based oils that do not contain water. They are used as is or “straight”
without being diluted. Straight oils are used in metalworking applications
where lubricity is more critical than heat reduction.
• They are composed of a base mineral oils or petroleum oil,
Fatty oils and Combination of mineral and fattly oils
• It contains polar lubricants such as fats, vegetable oils and
esters as well as extreme pressure additives such as Chlorine,
Sulphur and Phosphorus.
• Straight oils provide the best lubrication and the poorest
cooling characteristics among cutting fluids. ( Low C.S)
 3.3 Cutting Fluids
Types of Cutting Fluids
Straight Oils

Straight Cutting Oil Additive,

Color : Transparent
240 /Kilogram Straight Cutting Oil
₹ 140/ LTR
 3.3 Cutting Fluids
Types of Cutting Fluids
Soluble Oil
• The concentrate consists of a base mineral oil and
emulsifiers to help produce a stable emulsion.
• They are used in a diluted form (usual concentration = 3 to
10%) form an emulsion when mixed with water.
• Provide good lubrication and heat transfer performance.
• They are widely used in industry and are the least
expensive among all cutting fluids.
 3.3 Cutting Fluids
Types of Cutting Fluids
Soluble Oil

STAROL Water Soluble Water-soluble

Cutting oil (Metal Working cutting fluid
Fluid) (20 L) - Rs 3,200. SUPERCUT 1000
 3.3 Cutting Fluids
Types of Cutting Fluids
Soluble Oil

Grade: Mineral
Based Water
Soluble Cutting
Oil, Packaging
Type: Drum
₹ 154/ Litre
 3.3 Cutting Fluids
Types of Cutting Fluids
Synthetic Fluids
Synthetic metalworking fluids are water based solutions (or emilsions) of
synthetic lubricants (soaps and other wetting agents), corrosion inhibitors,
water softeners, EP, anti-bacteria additives (biocides), glycols and other
additives.
• contain no petroleum or mineral oil base
• are formulated from alkaline inorganic and organic
compounds
• They are generally used in a diluted form (usual
concentration = 3 to 10%).
• Synthetic fluids often provide the best cooling performance
among all cutting fluids.
 3.3 Cutting Fluids
Types of Cutting Fluids
Synthetic Fluids

Dynaflux - All Metal Synthetic Cutting Fluids Ca/4 All

Metal Syntheticcutting Fluid: 368-372-4X1 - ca/4 all
Synthetic Cutting Fluids
metal syntheticcutting fluid : Industrial & Scientific
₹350.00 INR
 3.3 Cutting Fluids
Types of Cutting Fluids
Semi-synthetic Fluids
• are essentially combination of synthetic and soluble oil
fluids
• Have characteristics common to both types.
• The cost and heat transfer performance of semi-synthetic
fluids lie between those of synthetic and soluble oil fluids.
 3.3 Cutting Fluids
Types of Cutting Fluids
Semi-synthetic Fluids

Semi Synthetic Cutting Oil, Pack

Size: 20 Liters: ₹ 140/ Litre
 3.3 Cutting Fluids
Compostion of cutting fluids
The cutting fluids may contain the following
• Base oil
• Emulsifier
• Corrosion inhibitors (for non-ferrous alloys) and rust
inhibitors (ferrous alloys)
• Lubricating, anti and extreme pressure additives
• Neutralizing agents
• Biocides and fungicides
• Foam inhibitors
• Stabilizing agents
 3.3 Cutting Fluids
Compostion of cutting fluids
Additive Function

Mineral oils and other hydrocarbons Base oils

Polyglycoether (for water soluble oils) Emulsifier

Aliphatic amines(for water soluble Neutralizing agent

oils)
Aliphatic amines in neutralized form Corrosion protection
Sulfonates Corrosion protection and
Extreme pressure additive
Fatty acid amides Lubricity improvement
Sulfur / Phosphorous compounds Extreme pressure additives
Aldyhyde Derivatives Biocides
 3.3 Cutting Fluids
Compostion of cutting fluids
The following substances used earlier as additives have
cancer generating potential and therefore, should be
discarded.
1. N-Nitrosamines and polyClorinated biphenyl
2. Benzo(a)pyrene
3. Chlorinated paraffins
Besides there are other substances earlier used as additives
have now come under the category of special wastes. Their
use increase the cost of disposal.
 3.3 Cutting Fluids
Method of applying cutting Fluids
The principal methods of cutting fluid application
include…

a flood of
cutting fluid is
applied on the
workpiece
 3.3 Cutting Fluids
Method of applying cutting Fluids
The principal methods of cutting fluid application
include…

a jet of cutting
fluid is
applied on the
workpiece
 3.3 Cutting Fluids
Method of applying cutting Fluids
The principal methods of cutting fluid application
include…

cutting fluid is
atomised by a
jet of air
 3.3 Cutting Fluids
Benefits Achieved With The Use Of Cutting Fluid

1. Reduction of cutting forces and energy consumption

2. improving tool life,
3. improving surface finish,
4. Easy removal of chips
5. Less distortion of workpiece
6. Lubrication of machine tool side ways
7. Finished surfaces are protected from corrosion
 3.3 Cutting Fluids
Cutting Fluid Health Hazards
Workers are exposed to metal cutting fluids via three
routes


1. Skin exposure
2. Aerial exposure
3. Ingestion
 3.3 Cutting Fluids
Skin exposure is the main problem – 80%
Main cause of occupational contact dermatitis

Solution ????
• Avoid prolonged contact
• e.g. Splash guards…
• we can use face protectors,