Introduction

• During metal cutting process, metal is removed in the

form of chips

• The friction between the tool and the chip causes the
temperature to rise

• This temperature is so high and leads to welding of chips

on to the tool face and work piece

• Thus reducing the tool life and efficiency of machining

1
 Introduction (contd.)
• Also the rise in temperature causes deformation of work
piece and leads to change in grain structure
• Thereby varying properties of work piece
• To overcome the above it is a must to have some means
to reduce friction
• This is achieved by the use of
 cutting fluids
 coolants
 lubricants
• The above action
 increases the machining efficiency
 tool life and
 provide free movement between mating parts

2
 Cutting fluids

Definition :

• Any substance that is applied to the cutting zone during

metal machining operation is called cutting fluid

• Term ‘Cutting Fluid’ denotes to those coolants and

lubricants that are used in metal machining

9M306.41 3
 Functions Of Cutting Fluids

• To obtain best surface finish and dimensional accuracy

• To carry away the heat that is generated during

machining

• Cool the tool and the work piece

9M306.41 4
 Functions Of Cutting Fluids (Contd.)

• To improve the machinability

• To prevent adhesion of chips to the tool and work piece

• To flush away chips from the cutting zone

• To reduce the friction at chip-tool and work-tool interface

9M306.41 5
 Properties Of Cutting Fluids
• To get the optimum benefits ,the cutting fluid should
posses the following qualities
- Possess good lubricating properties

- High heat absorption capacity

- No fire or accidental hazards

9M306.41 6
 Properties Of Cutting Fluids (Contd.)

• Not to emit toxic odors and vapours harmful to the

operator

• Should be non-poisonous

• Low viscosity

9M306.41 7
 Properties Of Cutting Fluids (Contd.)

• Prevent rusting of the machine and working surfaces

• Should not produce fog, smoke during use

• Suitable for a variety of cutting operations

• Should not discolor the finished work piece

9M306.41 8
 Properties Of Cutting Fluids (Contd.)

• Chemically stable

• Should impart anti welding properties

• High flash point

• Should not deteriorate in storage

9M306.41 9
 Types Of Cutting Fluids

• The cutting fluids are classified into five main groups

- Water soluble oils or compounds
- Straight oils (mineral oils and fatty oils)
- Chemical-additive oils (sulphurised oils and
chlorinated oils)
- Chemical compounds
- Solid lubricants

9M306.41 10
 Selection of cutting fluids

• The selection of a proper cutting fluid for any

particular application depends on
- Cutting tool material
- Work piece material
- Operation being performed
- Cost factor
- Service expected
- Cutting condition

9M306.42 11
Cutting Fluids For Different Operations And Different
Materials With HSS Tool

           

Process Turning Grinding Milling Broaching

 
  Material
 
 
 
  Drilling
 
  Planning
 
 
Sawing  
 

           
      Kerosene   Soluble oil    

Aluminum Soluble oil Suphochlorinated oil

 
 
 
 
 
 
Lard oil  
 
Lard oil  
 
 
 

Soluble oil Mineral Oil Soluble oil

           

Suphochlorinated oil
COPPER Dry Dry soluble oil soluble oil l

  soluble oil soluble oil      

    Kerosene      
           

BRASS Dry Dry Dry    

  soluble oil soluble oil soluble oil soluble oil Sulphochlorinated oil
    Kerosene      
           
           
           

BRONZE Dry Dry Dry   Sulphochlorinated oil

  soluble oil soluble oil soluble oil soluble oil  

    Lard oil Lard oil    

    Mineral Oil Mineral Oil    

9M306.42 12
Cutting Fluids For Different Operations And Different
Materials With HSS Tool (Contd.)

High Sulphurised fatty

CAST IRON Dry Dry Dry soluble oil chlorinated oil

  soluble oil Air jet soluble oil    

    soluble oil      
           

High Sulphurised fatty

PLAIN CARBON STEEL soluble oil soluble oil soluble oil soluble oil chlorinated oil

    Sulphurised oil Sulphurised oil    

    Lard oil Lard oil    

    Mineral Oil Mineral Oil    

           

HIGH CARBON STEEL          

  soluble oil soluble oil      

    Sulphurised oil soluble oil soluble oil  

    Lard oil Mineral Oil   High Sulphurised fatty chlorinated oil

    Mineral Oil      

9M306.42 13
 Merits Of Cutting Fluids And Coolants

• To carry away chips

• To drive away scale and dirt
• To improve surface finish
• To protect the finished surface from corrosion
• To increase the tool life
• Improve machinability
• Reduce machining forces
• Provide lubrication
• Provides cushioning effect between the tool and work
piece
9M306.42 14
 Methods

– Methods of application of cutting fluids

• Flood method
• Jet method
• Mist method

9M306.43 15
 Flood Method
 A reciprocating pump is used to force the coolant
over the work piece and tool
 The out let of the pump is connected to a nozzle
through a flexible pipe
 The nozzle can be adjusted to direct the stream of
the fluid at cutting zone
 This is the most common method of application of
cutting fluid

9M306.43 16
Flood method

9M306.43 17
 Jet Method

• A small jet of fluid at high speed is directed at the point of

metal supporting from the underneath

APPLICATION OF CUTTING FLUID

• In high speed jet system gear or vane type pump

is used to maintain high pressure
9M306.43 18
Jet method

9M306.43 19
Jet method

9M306.43 20
 Mist Method

 The fluid is passed through a specially designed

nozzle to form very fine droplets (mist)

 This mist is directed to the cutting zone at high speed

 It has better cooling effect than flood or jet method

9M306.43 21
Mist method

9M306.43 22
 Lubricants

• A cutting fluid which is used for the purpose of reducing

friction between the contacting surfaces in the cutting

zone is called lubricant

• Lubricants help in reducing the heat generated during

the machining processes

9M306.44 23
Lubricated headstock

9M306.44 24
 Lubricants (contd…)
• Machine tools such as lathes, milling ,drilling, shaping
etc perform satisfactorily if they are properly lubricated
• The parts of machine tools which need lubrication are,
• slide ways
• gear boxes

• spindles

• bearings

• mating parts etc

9M306.44 25
 Purpose of Lubricants

 To reduce the friction between cutting tool and the

material being cut

 To minimize the heat generated during operation

 To prevent rise in temperature

 To reduce wear

9M306.44 26
 Purpose of Lubricants (contd…)

• To increase tool life

• Provide cushioning effect against vibrations

• To drive away chips, scale and dirt between the

mating parts

• Protect finished surfaces from corrosion

9M306.44 27
 Lubrication of Machine Tools

• Purposes

• Machine tools give satisfactory performance if they

are properly cleaned and lubricated

• Slide ways , gear boxes and spindle bearings must

be lubricated to minimize friction

• Lubrication of slide ways protects the surface from

wear 9M306.46 28
 Lubrication of Machine Tools

• Purposes

• If the mating parts are well lubricated , the movement

of slides will be precisely controlled

• Ball and roller bearings are lubricated to minimize the

friction and to protect from rust and wear

9M306.46 29
 Properties Of Lubricants

• Viscosity

• Oiliness

• Flash and fire point

• Pour (freezing) point

• Chemical stability

• Carbon residue

9M306.44 30
 Properties Of Lubricants (contd…)

• Viscosity
 It is the measure of resistance of the oil to flow

 The oil used as lubricant must have sufficient

viscosity that it is not squeezed out from two
surfaces

9M306.44 31
 Properties Of Lubricants (contd…)
• Oiliness
 The ability of the oil to wet the metallic surface is
called oiliness
 Lubricants with good oiliness prevent the break down
of the oil film and reduce the wear

9M306.44 32
 Properties Of Lubricants (contd…)

• Flash and Fire point

• Flash point is the lowest temperature at which an
oil gives off sufficient vapour to support momentary
flame

• Fire point is the temperature at which an oil gives

vapour to burn it continuously when ignited

• Flash and Fire point should be high for lubricants

9M306.44 33
 Properties Of Lubricants (contd…)

• Pour (freezing) Point

• This is the temperature at which an oil will cease to
flow when cooled
• It indicates the suitability of lubricant for use in cold
conditions such as in ice-making machines,
refrigerators etc
• Lubricants used in such conditions should possess
low pour point

9M306.44 34
 Properties Of Lubricants (contd…)

• Chemical Stability
 The lubricant must be chemically stable and must not
oxidize easily

 It should not be vaporized under working conditions

and should resist corrosion

9M306.44 35
 Properties Of Lubricants (contd…)
• Carbon Residue
• At high temperature lubricating oil decomposes and
deposits free carbon on the surface

• A good lubricating oil should deposit small amount of

carbon i.e. low carbon residue at high temperature

9M306.44 36
 Classification Of Lubricants

• Liquid lubricants
- Animal oils
- Vegetable oils
- Mineral oils
- Synthetic oils

• Semi-solid lubricants (Grease)

• Solid lubricants (Grease)
• Waxes

9M306.45 37
 Liquid Lubricants

• Animal oil (tallow oil, lard oil)

- They are obtained from animal fats
- Tallow oil is used in cold drawing
• Vegetable oils (castor oils, olive oils, rapeseed oil)
- These are extracted from seeds and trees
- Castor oil is used in automobiles
- Animal oils and vegetable oils are not widely used
in machine tools, since they get oxidized easily

9M306.45 38
 Mineral oil

• These oils are petroleum products and are most

commonly used because of their cheapness and stability

• They do not form emulsions with water

9M306.45 39
 Synthetic Oils
• Synthetic lubricant (polyalkylene glycols and silicon

fluids) possess good lubricating properties

• The high cost limits their applications

9M306.45 40
 Semi-solid Lubricants

• Grease forms an important semi-solid lubricant

• used when the fluidity of oil is undesirable

• It is an oil which has been thickened by soap

9M306.45 41
 Semi-solid Lubricants (contd.)

• It offers simplest method of lubrication with additional

advantages of preventing the entry of dirt
• In automobiles they are used where high temperatures
are encountered

9M306.45 42
 Semi-solid Lubricants (contd.)
• Advantages

• It is particularly suited to bearings at slow speed and

large clearances

• It provides seal against dust, grits and moisture

• It provides constant lubrication for a longer period

• In ball and roller bearings grease lubrication is

invariably used

9M306.45 43
 Semi-solid Lubricants (contd.)

• Disadvantages

 Grease provides very little lubrication until the bearing

temperature rises sufficiently to melt it

9M306.45 44
 Solid Lubricants

• Solid lubricants are used where oil film can not be

maintained due to high pressure or temperature

• Graphite is one of the best known solid lubricants

9M306.45 45
 Solid Lubricants (contd.)

• These are used in high temperature services

• These are not suitable for ball and roller bearings

9M306.45 46
 Waxes

• Are derived from petroleum

• They are compounded with fatty acids and soaps

• They are used under high pressure application

• Used during

• drawing

• rolling

• extrusion etc

9M306.45 47
 Methods of Lubrication

• Lubricating oil is generally applied to sliding parts with

the help of oil-can

• Lubricants are also applied by the following systems

- Gravity feed system

- Pressure feed system

9M306.46 48
A grease gun

9M306.46 49
 Gravity Feed System

• In this system lubricant is applied to the sliding and

mating parts through oil cups

• The oil cups are located at the higher levels of sliding

and mating parts

• In this system oil flows to the parts due to gravity

9M306.46 50
Gravity feed system

9M306.46 51
 Pressure Feed System

• This system is used generally in automobiles

• In this system lubricants are applied under pressure

by using oil pumps

• In this system oil pump is situated below the engine

9M306.46 52
Pressure feed system

9M306.46 53