Cutting Fluids

Requirements

Reduce friction and wear, thus improving tool life and the surface finish of the workpiece.
° Cool the cutting zone, thus improving tool life and reducing the temperature
° Reduce forces and energy consumption.
° Flush away the chips from the cutting zone, thus preventing the chips from interfering
with the cutting process,
° Protect the machined surface from environmental corrosion

Choice of Fluids
Type of machining operation
Tool and workpiece materials,
Cutting speed, and the method of application.
Order Of Severity ????(Inc or Decreasing)
sawing, turning, milling, drilling, gear
cutting, thread cutting, tapping, and internal broaching.
 Cutting Fluids

Cooling action --- of fluids can be detrimental.

chip to become more curly and thus concentrate the heat closer to the tool tip,
reducing tool life.

More importantly, in interrupted cutting operations, such as milling with

multipletooth cutters, cooling of the cutting zone leads to thermal cycling of the
cutter teeth, which can cause thermal cracks by thermal fatigue or thermal shock.
 Cutting-fluid Action

cutting fluid gains access to the tool-chip interface

by
seeping from the sides of the chip through the capillary action of the interlocking
network of surface asperities in the interface.

Because of the small size of this capillary network, the cutting fluid should have

a small molecular size and possess proper wetting (surface tension)

For example, grease cannot be an effective lubricant in machining, but low-molecular weight
oils suspended in water (emulsions) are very effective.
 Types of Cutting Fluids.

Oils (also called straight oils)

including mineral, animal, vegetable, compounded, and synthetic oils, typically are
used for low-speed operations where temperature rise is not significant.

Emulsions
(soluble oils), a mixture of oil and water and additives, generally are used for high-speed
operations because the temperature rise is significant.
The presence of water makes emulsions highly effective coolants. The
presence of oil reduces or eliminates the tendency of water to oxidise .
Semisynthetics are chemical emulsions containing little mineral oil, diluted in
water, and with additives that reduce the size of oil particles, making them
more effective.

Synthetics are chemicals with additives, diluted in water, and containing no oil.
 Methods of Cutting-fluid Application.

Flooding
Flow rates typically range from 10 L/min for single-point tools to 225 L/min per cutter for
multiple-tooth cutters, as in
milling. In some operations, such as drilling and milling,
fluid pressures in the range from 700 to 14,000 kPa are used to
flush away the chips produced
 Methods of Cutting-fluid Application.

Flooding
 Methods of Cutting-fluid Application.

Mist
cooling supplies fluid to inaccessible areas, better visibility of the workpiece
It is effective particularly with water-based fluids at
air pressures ranging from 70 to 600 kPa. However, it
has limited cooling capacity.
Mist application requires venting to prevent the inhalation of airborne fluid
particles by the machine operator and others nearby

High –pre ssure systems

Liquid is nozzle sprayed at pressure 5.5 to 35 Mpa at the clearance or relief face of
the tool
 Near-dry and Dry Machining

Alleviating the environmental impact of using cutting fluids, improving air quality
in manufacturing plants, and reducing health hazards.
Reducing the cost of machining operations, including the cost of maintenance,
recycling, and disposal of cutting fluids.
 Further improving surface quality.

The mixture is delivered to the cutting zone through the spindle of the machine tool,
typically through a 1-mm-diameter nozzle and under
a pressure of 600 kPa.
Supply is scant of the order of 1 to 100 cc/hr
one ten-thousandth of that used in flood cooling
Dry machining
turning, milling, and gear cutting on steels, steel alloys, and cast irons. Not fit for
Aluminum.
 Near-dry and Dry Machining

High-pressure systems
 Near-dry and Dry Machining

Through the cutting tool system

narrow passages can be produced in cutting tools, or toolholders,

 Effects of Cutting Fluids.

° Workpiece material and machine tools

° Biological considerations
° The environment.

Workpiece material and machine tools

(a) cutting fluids containing sulfur should not be used with nickel-based alloys

(b) fluids containing chlorine should not be used with titanium.

Biological considerations
constituents such as sulfur, chlorine, phosphorus, hydrocarbons, biocides, and various
additives can cause
severe skin reactions
and respiratory problems
The environment.
Growth of microbes(bacteria, molds, and yeast)
Effects of Cutting Fluids.
 Dry machining

flush chips– by pressurized air.

The compressed air doesn’t serve a lubrication purpose but facilitate limited cooling

Cryogenic machining
Cryogenic gases such as nitrogen or carbon dioxide as a coolant.
-200oC liq. Nitrogen into cutting zone

Because of Low Temperature:

Hardeness √ Higher cutting speeds.
Brittle chips
 Effects of Cutting Fluids.

A machining operation is being carried out with a cutting fluid that is an effective
lubricant. What will be the changes in the mechanics of the cutting operation if
the fluid is shut off?

Friction at the tool-chip interface will increase

The shear angle will decrease in accordance??? equation of shear angle
The shear strain will increase, as seen from?? Write equation of shear angle
The chip will become thicker.
A built-up edge is likely to form.

Outcome

The Shear energy in the primary Zone will increase.

The frictional energy in the secondary zone will increase.
The total energy will increase.
The temperature in the cutting zone will rise, causing greater tool wear.
Surface finish will begin to deteriorate
 QUALITATIVE PROBLEMS

22.l8. Why does temperature have such an important effect

on tool life?

22.19. Ceramic and cermet cutting tools have certain advantages over carbide tools.
Why, then, are they not completely replacing carbide tools?

22.20. Can cutting fluids have any adverse effects in machining? If so, what are they?

22.2|. Describe the trends you observe in Table 22.2.

22.22. Why are chemical stability and inertness important in cutting tools?