UNIT – 4

IN THIS ONLY 2 THREE MARK QUESTION THEY WILL COME FOR

BOARD EXAM.
Cutting Fluid is defined as the substance which may be a solid, liquid or gas applied
between the tool and work materials to reduce the friction between them.

The main disadvantage of cutting fluid is that the fluid system becomes costlier due to
incorporation of filtering, pumping and collection system.

The cutting fluids are sometimes called as coolant or lubricant.

Coolant: A cutting fluid used to cool the tool and work piece is called coolant. Water based
fluids are most effective for cooling the tool and work piece due to higher specific heat and
thermal conductivity.

Lubricant: A cutting fluid used for the purpose of diminishing friction between the
contacting surfaces in the cutting zone is called lubricant. Oil based fluids are the better
lubricants because they are stable at high temperature.

Types of cutting fluids:

i. Solid Cutting Fluids:

These are employed as finely divided particles and are kept in a suspension state in liquid,
by means of a dispersing agent. The most convenient means of applying these lubricants to
the cutting tools are in the form of sticks waxes and bar soaps, but their applications are
limited to tapping and sawing operations. Example: Graphite.

ii. Liquid Cutting Fluids:

a) Water Solutions:
Water is an excellent cooling medium, as it possesses maximum specific heat.
But it is rarely used because it produces rust, corrosion and low lubricant
properties.
b) Oil based cutting Fluids
These are also known as straight oils. They may be mineral oils of any
viscosity or fatty oils. It is use for automatic screw machine and light
machining operations works. The different oils used are soluble oil, straight
fatty oil, mineral oil, etc.
iii. Gaseous Types of cutting Fluids:
In gaseous cutting fluids, air, carbon dioxide and argon are the most commonly used.
Air is used in limited applications such as grinding and metal cutting processes,
 whereas CO2 possesses an excellent heat extracting property and is applied to low
machining and high strength thermal resistant alloys
iv. Chemical Coolants
It consists of a number of chemical components dissolved in water. It is particularly
used for grinding operations. Rust inhibitor such as sodium nitrate is mixed with high
percentage of water to obtain the chemical compounds. They are classified into three
types,
a. Pure coolants
b. Coolants and lubricants
c. Lubricating coolants
v. Soluble oils:
It is used for steel wrought iron and aluminium materials.

Properties of Cutting Fluids:

 High specific heat, conductivity of head and film coefficient.

 It should possess sufficient lubricating properties, to reduce frictional forces and to
decrease the power consumption.
 It should be odourless
 It should be non-corrosive to work and machine.
 Low viscosity to allow free flow of liquid.
 Non-toxic to an operator
 It should permit clear view of work, which is desirable in precision work.
 Stable in use and storage.
 It should be safe particularly with regards to fire and accident hazards.

Properties of Lubricants:

 Viscosity is defined as the property of a fluid, which offers resistance to the flow of
one layer of fluid over the other. It is the measure of degree of fluidity of a liquid.
 Oiliness is defined as the tendency of lubrication, due to which oil can stick on to the
surface of the machine parts. The machine with oiliness can operate under heavy load
and pressure.
 Flash point is defined as the lowest temperature point, at which the lubricant
produces sufficient vapours and ignites for a moment, when subjected to a standard
flame.
 Fire Point is defined as the lowest temperature point, at which the lubricant burns
continuously for at least 5 seconds, when subject to a standard flame.
  Corrosion Stability: Good lubricating oil should not corrode metals. As the
lubricating oil is frequently employed and is in contact with the copper and brass
system, its properties should be checked thoroughly by copper corrosion test and steel
corrosion test.

Functions of cutting fluid are:

 It is used to cool the cutting tool and work piece.

 It is used to lubricate the tool, chip and work piece.
 It is employed to prevent the formation of built-up edge on work piece.
 The use of cutting fluids helps in lubricating the relatively moving parts.
 It increases the surface finish of work piece.
 It protects the work material from corrosion.
 It helps to carry away the chips.

Fluids and coolants required in turning, drilling, shaping, sawing & broaching.

TYPES OF MATERIAL
Machining Cast Hard
Soft Steel Brass Bronze Aluminium Copper
operations Iron Steel
Cooling Mineral Mixture
compound, Mineral oil + Mineral of lard oil
Turning Dry Kerosene
cutting oil, lard oil 10% lard oil and
soap water fatty oil. turpentine
Dry,
Kerosene, Cooling
Dry or
Any strong Dry or compound
Drilling Dry Dry any
Coolant soda Kerosene lard oil
coolant
water and
turpentine
Soap
Mineral
Shaping Dry water, Dry Dry Kerosene Dry
lard oil
soda water
Sawing Soluble oils
Broaching Minerals oils or soluble oils

Selection of cutting Fluids:

 The type cutting fluid to be employed depends upon the work material and the
characteristics of the machining process.

The selection of a particular type of cutting fluid depends on the following factors.

i. Type of machining operation like turning, drilling/grinding, sawing,

broaching, shaping, planning, milling.\
ii. Metal removal rate
iii. Type of work piece material
iv. Type of tool material
v. Surface finish required
vi. Cost of cutting fluid
vii. Viscosity of cutting fluid.

Methods of application of cutting fluid:

1. Manual Method
2. Drip tank method
3. Pump method
a. Flood or high jet method
b. Mist method

Manual Method:

In this method, the cutting fluid is applied on cutting tool by hand, with the help of
brush.

Drip Tank Method:

In this method, a drip tank is connected to the machine body. The fluid is applied to
the cutting tool from the tank.

Pump Method:

In this method cutting fluid is applied on the tool, with the help of pump.

Flood or High Jet Method

A flood or high jet method is a continuous process of supplying cutting fluid to the
cutting tool. In this method, a nozzle is used , which directs the fluid on the cutting zone.
After cooling the work piece and tool, the fluid is collected in a lower tank and is recirculate
with the help of a pump. The chips and dirt during recirculation are prevented by using filters.
A high jet method increases the life of tool but due to high pressure, it is hazardous for the
operator. In addition, this method is more expensive as it requires costly apparatus for
supplying the cutting fluid.

Mist Method

This method works on the principle of venture meter. It consists of a tank, siphon
nozzle and on-off valve. In this method air and finely atomized liquid droplets are mixed
together (mist) and is used as a cutting fluid. The fluid is directed to the cutting zone at very
high velocities. The size of liquid droplets varies from 10micrometer to 25 micrometre. The
air from the tank flows to the nozzle through a siphon tube, which draws the fluid into the
nozzle. Hence the cutting fluid is supplied to the tool with high velocity through nozzle.
 Classification of lubricant (solid, liquid, gaseous)

Sl
Classification Description Sub classification Examples
No.
Solid lubricants are the
i. Structural
materials, in the form of
ii. Mechanical
solid phase, used to reduce i. Graphite
Solid iii. Chemically active
1 friction, where the ii. Molybdenum
lubricants iv. Refractories, ceramics &
maintenance of oil film is disulphide.
glasses
unusual due to high
pressure and temperatures
2 Liquid Liquid lubricant is a i. Vegetable oils i. Palm oil
lubricants continuous fluid film ii. Animal oils ii. Castor oil
supplied between the iii. Mineral oils
rubbing surfaces, to reduce iv. Blended oils
friction between them v. Synthetic oils
3 Semi-solid Semi-solid lubricants i. Grease
lubricants possess high viscosity than ii. Vaseline
the liquid lubricants and
are used when liquid
lubricant (like oil) cannot
remain in place.

1. How does cutting fluid improve tool life?

Cutting fluids plays an important role in improving the machine tool life by,
i. Cooling the tool and work piece without which the tool loses its hardness at
higher temperatures
ii. Decreasing the adhesion between the chip and tool and removing the built up
edge formed.
iii. Providing lubrication, due to which less heat is generated at the tool tip.
2. Write any three factors to be considered while selecting the cutting fluids

The selection of a particular type of cutting fluid depends on the following factors.
 i. Type of machining operation like turning, drilling/grinding, sawing,
broaching, shaping, planning, milling.
ii. Metal removal rate
iii. Type of work piece material
iv. Type of tool material
v. Surface finish required
vi. Cost of cutting fluid
vii. Viscosity of cutting fluid.
3. State the purpose of lubrication/ cutting fluids
a. To reduce the friction between cutting tool and the material being cut
b. To minimize the heat generated during operation
c. To prevent rise in temperature
d. To reduce wear
e. To reduce the friction between cutting tool and the material being cut
f. To minimize the heat generated during operation
g. To prevent rise in temperature
h. To reduce wear
4. State the functions of cutting fluids
 It is used to cool the cutting tool and work piece.
 It is used to lubricate the tool, chip and work piece.
 It is employed to prevent the formation of built-up edge on work piece.
 The use of cutting fluids helps in lubricating the relatively moving parts.
 It increases the surface finish of work piece.
 It protects the work material from corrosion.
 It helps to carry away the chips.
5. State the difference between a coolant and a lubricant
Sl No Coolant Lubricant
1 Coolant is to take away generated Lubricant is to reduce coefficient of
cutting heat from the cutting zone, and friction between surface of cutting tool
thereby keep the cutting zone and work piece and thereby minimize
temperature low. rate of heat generation
2 Coolant acts on the generated heat. It Lubricant can reduce the rate of heat
cannot reduce rate of heat generation generation. It has no influence on
removing heat that is already generated.
3 Coating on cutting tool has no role as Coating layer on cutting tool sometimes
coolant acts as lubricant
4 To act as good coolant the cutting To act as good lubricant the cutting fluid
 fluid should possess high specific heat should possess high lubricity.
capacity

6. Write a short note on straight oils.

Straight oils, also known as neat cutting oils or straight cutting oils, are unblended or
pure oils used in various industrial machining and metalworking processes. They are
typically mineral-based or synthetic oils that serve as coolants and lubricants during
operations like cutting, drilling, milling, and grinding of metals

7. State the classifications of lubricants

The lubricants are classified into three types,
i. Solid lubricants. Example : Graphite
ii. Liquid Lubricant: Example: Vegetable oil, mineral oil, synthetic oil,
animal oil.
iii. Semi-solid lubricants. Example: Grease.

8. List out the different types of cutting fluids used in machining.

 Soluble oil
 Mineral oil
 Mineral lard oil
 Fatty oil
 Soap water
 Soda water
 Kerosene
 Turpentine
9. What are the applications of lubricants?
i. It acts as a cooling medium, corrosion preventer and heating agent.
ii. It is used for minimizing the friction between mating surfaces.
iii. A semi-solid lubricant, such as grease is used in rail axle boxes, bearings and
gears.
iv. Solid lubricants are used in commutator brushes of electric generators and
motors. Example: Graphite and molybdenum disulphide.
10. State any three properties of cutting fluids
 Viscosity.
 Oiliness
 Flash point
  Fire Point
 Corrosion Stability
11. What is a cutting fluid? State primary function of a cutting fluid?
Cutting Fluid is defined as the substance which may be a solid, liquid or gas applied
between the tool and work materials to reduce the friction between them
 It is used to cool the cutting tool and work piece.
 It is used to lubricate the tool, chip and work piece.
 It is employed to prevent the formation of built-up edge on work piece.
 The use of cutting fluids helps in lubricating the relatively moving parts.
 It increases the surface finish of work piece.
 It protects the work material from corrosion.
It helps to carry away the chips
12. How the cutting fluids reduce the temperature in metal cutting?

Cutting fluids act as lubricants between the cutting tool and the work piece. This
reduces friction and wear on the tool, leading to longer tool life. Reduced friction also
means less heat is generated during the cutting process.