Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel

The influence of minimum quantity of lubrication (MQL) on cutting temperature, chip and dimensional accuracy in turning AISI-1040 steel

Effects and mechanisms in minimal quantity lubrication machining of an aluminum alloy

Traditionally, metal working fluids (MWF) are known to improve machining performance despite poor ecological and health side effects. A new sustainable process that has minimized the use and application of MWFs is NDM (near dry machining). Although there is much controversy on the effectiveness of NDM, it is agreed that a lack of science-based modeling prevents its widespread use. This paper presents a new method to predict tool-wear/tool-life performance in NDM by extending a Taylor speed-based dry machining equation. Experimental work and validation of the model was performed in an automotive production environment in the machining of steel wheel rims. Machining experiments and validation of the new equation reveal that tool-wear can be predicted within 10% when the effect of NDM is statistically different than dry machining. Tool-wear measurements obtained during the validation of the model showed that NDM can improve tool-wear/tool-life over four times compared to dry machining which underlines the need to develop sustainable models to match current practices.

A comprehensive tool-wear/tool-life performance model in the evaluation of NDM (near dry machining) for sustainable manufacturing

In all machining processes, tool wear is a natural phenomenon and it leads to tool failure. The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Metal cutting fluid changes the performance of machining operations because of their lubrication, cooling and chip flushing functions, but the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. The minimization of cutting fluid also leads to economical benefits by way of saving lubricant costs and workpiece/tool/machine cleaning cycle time. The concept of minimum quantity lubrication (MQL) has been suggested since a decade ago as a means of addressing the issues of environmental intrusiveness and occupational hazards associated with the airborne cutting fluid particles on factory shop floors. This paper deals with experimental investigation on the role of MQL by vegetable oil on cutting temperature, tool wear, surface roughness and dimensional deviation in turning AISI-1060 steel at industrial speed-feed combinations by uncoated carbide insert. The encouraging results include significant reduction in tool wear rate, dimensional inaccuracy and surface roughness by MQL mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction.

Performance evaluation of minimum quantity lubrication by vegetable oil in terms of cutting force, cutting zone temperature, tool wear, job dimension and surface finish in turning AISI-1060 steel

In spite of the manifold efforts to reach a total renouncement of the use of cooling lubn'cants in metal cuttingfor en­ vironmentally reasons, cooling lubrication is an essential condition to achieve an economical tool life and the re­ quired surface quality in many cases. Against this background, the minimum quantity cooling lubrication is an interesting possibility for an economical and environmentally compatible production which combines the functional­ ity of the cooling lubrication with an extremely low consumption of cooling lubricants. With help of various results achieved in turning, milling and broaching experiments, this report describes the possibilities of application of mini­ mum quantity cooling lubricating systems in machining with geometrically defined cutting edges.

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Dieter Spath

Papers

Application of minimum quantity cooling lubrication technology in cutting processes