Showing papers on "Cutting fluid published in 2005"

A review of cutting fluid application in the grinding process

Abstract: It is generally accepted that heat generation is the limiting factor in the grinding process due to the thermal damage associated with it. To combat this energy transfer, a cutting fluid is often applied to the operation. These cutting fluids remove or limit the amount of energy transferred to the workpiece through debris flushing, lubrication and the cooling effects of the liquid. There have been many new and exciting systems developed for cutting fluid application in the grinding process. This paper reviews some of the common as well as some of the more obscure cutting fluid systems that have been employed in recent years with an emphasis on creep-feed applications. The review also suggests possible avenues of future research in cutting fluid application for the grinding process.

Study on the behavior of the minimum quantity lubricant - MQL technique under different lubricating and cooling conditions when grinding ABNT 4340 steel

Abstract: Energy consumption, air pollution and industrial waste have received special attention from public authorities in recent years. The environment has become one of the most important subjects in the context of modern life, for its deterioration impacts the quality of life populations. Driven by pressure from environmental agencies, politicians have drawn up ever stricter laws aimed at protecting the environment and preserving energy resources. All these factors have led industry, research centers and universities to focus their efforts on researching alternative production processes, creating technologies to minimize or avoid the production of environmentally aggressive residues. Up to a few years ago, the main objective of manufacturing plants was to produce goods aimed at satisfying technological and economic aspects. Green, or "dry" machining and Minimum Quantity Lubricant (MQL) machining have caught the attention of researchers and technicians in the area of machining as an alternative to traditional fluids. Thus, this work proposes to explore the MQL concept in the grinding operation. Although its advantages allow one to predict a growing range of applications for MQL, the variables of influence to be considered and the effects on the results of the process have so far been little studied. Grinding involves several input parameters but, to date, little attention has been focused on the form and quantity of cutting fluid applied to the process. The condition and rate of cutting fluid applied directly influences some of the process's output variables. This work, therefore, analyzes the behavior of the MQL technique under different lubrication and cooling conditions, developing an optimized fluid application methodology based on the creation of a special nozzle through which a minimum amount of oil is pulverized in a compressed air stream. The evaluation of the technical performance of MQL in grinding, using aluminum oxide and superabrasive CBN (cubic boron nitride) grinding wheels, consisted of an experimental analysis of the behavior of the tangential cutting force, G ratio, roughness and residual stress. The results presented herein allowed us to evaluate the behavior of the MQL technique in the grinding process, thus contributing toward an environmentally friendly technology.

Research on experiments and action mechanism with water vapor as coolant and lubricant in Green cutting

Abstract: Green cutting has become focus of attention in ecological and environmental protection. Water vapor is cheap, pollution-free and eco-friendly. Therefore water vapor is a good and economical coolant and lubricant. Water vapor generator and vapor feeding system were developed to generate and feed water vapor. Comparative experiments were carried out in witch YT15 (P type in ISO) tool was used in cutting C45 steel under the conditions of compress air, oil water emulsion, water vapor as coolant and lubricant and dry cutting, respectively. The experimental results showed that with water vapor as coolant and lubricant the cutting force is further reduced, the friction coefficient, the chip deformation coefficient and the surface roughness value decreased and the cutting temperature lowered. Kinetic model of penetration capillary in tool–chip interface of cutting fluid revealed that the lubricity effect is much better with water vapor as coolant and lubricant because of its excellent penetration performance and forming of low shearing strength lubrication layer. Therefore, the use of water steam as coolant and lubricant proves to be a green cutting technique.

The effects of austempering temperature and time onto the machinability of austempered ductile iron

Abstract: Heat treating the ductile cast iron produced austempered ductile iron (ADI), which has outstanding mechanical properties that can be varied over a wide range by varying the heat treatment parameters. In the present work a series of test were conducted and the effects of austempering temperature and times onto the material properties was investigated. The machinability of ADI was evaluated by comparing tool life, tool wear rate, cutting forces, and surface finish produced on a job as general criteria. Machinability tests were carried out following ISO 3685: 1993 (E) standard “Tool Life Testing with Single Point Turning Tools”. The cutting force data used in the analyses were gathered by a tool breakage detection system that detects the variations of the cutting forces measured by a three-dimensional force dynamometer. Six pairs of ductile iron specimens, austempered at 300, 350 and 400 °C for 1 and 2 h were tested. The cutting tools used in the tests were coated carbide inserts, ISO SNMG 120408 (K10), clamped on tool holders CSBNR 2525 M12. No cutting fluid was used during the turning operations. During the experiments cutting forces, flank wear and surface roughness values were measured throughout the tool life and the machining performance of ADI having different structures were compared.

Development of Nozzle System for Oil-on-Water Droplet Metalworking Fluid and Its Application to Practical Production Line

Abstract: A new nozzle system which consists of a discharge nozzle and supply equipment has developed for environmental friendly metalworking fluid, called oil-on-water droplet metalworking fluid. This system provides excellent cutting performances in terms of roughness on finished surfaces, burr dimensions and cutting force in both aluminum alloy and stainless steel milling. As its application to practical use, the system has been employed for grooving process in the production line of engine main bearings which was conventionally machined under dry condition. It has been shown that the developed system can improved the machining performances in terms of machining error and tool life. The improvement for the machining error leads to significant reduction in the rejection of defective parts in the production line and more than twofold increase in tool life is obtained.

Rotary cutting tool

Abstract: PROBLEM TO BE SOLVED: To provide a rotary cutting tool capable of efficiently supplying cutting fluid to a knife edge of a cutting blade. SOLUTION: It is possible to efficiently supply the cutting fluid to the knife edges of all the cutting blades 11 as this rotary cutting tool has a single first channel 50 to introduce the cutting fluid to the inside of a tool main body 2, a single second channel 51 to open toward each of more than two of the cutting blades 11 and more than two of connecting channels 61A to 61D smoothly communicating end parts of the first channel 50 and the second channel 51 through to each other and making a curved line. It is possible to extremely facilitate and reduce cost of molding of the connecting channels 61A to 61D by forming the connecting channels 61A to 61D on a connecting member 60 installed on the tool main body 2 free to connect to and disconnect from it. COPYRIGHT: (C)2006,JPO&NCIPI

The influence of minimum quantity of lubrication (mql) by vegetable oil-based cutting fluid on machinability of steel

Abstract: 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 fluids 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. Because of them some alternatives has been sought to minimize or even avoid the use of cutting fluid in machining operations. Some of these alternatives are dry machining and machining with minimum quantity of lubrication (MQL). This paper deals with experimental investigation on the role of MQL on cutting temperature, tool wear, surface finish and dimensional deviation in turning of AISI-1040 steel at industrial speed-feed combinations by uncoated carbide insert. The encouraging results include significant reduction in cutting temperature, tool wears and dimensional inaccuracy by MQL mainly through favorable chip-tool and work-tool interaction.

Air blowing and mist collection systems in machine tool

Abstract: PROBLEM TO BE SOLVED: To provide air blowing and mist collection systems in a machine tool in which a cutting scrap or a cutting fluid adhering to an object to be processed is removed by air blowing and mists generated during processing are collected in a processing chamber. SOLUTION: There is provided a machine tool in which an object to be processed is subjected to processing such as drilling and mists generated from a cutting fluid is adapted to collect with a mist collection system attached in a processing chamber, wherein a nozzle of an air blowing system 20 is provided on the portion for supporting a main spindle mounting a cutting tool; and a mist collection system 30 in which a disk type rotating brush 45 and an overshooting member 50 are fixed on a main spindle 41 disposed in a separation tank 31, an exhaust port of a cyclone 52 disposed in the downstream side of the overshooting member is disposed so as to connect to a suction pipe of a suction means 60, wherein a cutting scrap or a cutting fluid adhering to an object to be processed is blown off and removed by pressurized air ejecting from the nozzle and mists in air sucked from the processing chamber are separated in a separation tank. COPYRIGHT: (C)2006,JPO&NCIPI

Waste sand treating method in crystal processing

Abstract: The process of treating waste crystal processing sand with cutting fluid, iron and its oxide, crystal powder, SiC, crystal bits, etc. includes the following steps: 1. eliminating the oily cutting fluid, 2. sieving out crystal bits and other large grain impurity, 3. alkali washing to eliminate SiO2, 4. water washing and regulating pH value, 5. acid pickling to eliminate iron and its oxide and to separate reaction liquid and precipitate, 6. water washing and grading the precipitate, 7. drying, 8. packing the dried SiC material, and 9. neutralizing the reaction liquid and draining.

Dry Machinability of Aluminum Alloys

Abstract: Adverse effects of the use of cutting fluids and environmental concerns with regard to cutting fluid disposability is compelling industry to adopt Dry or near Dry Machining, with the aim of eliminating or significantly reducing the use of metal working fluids Pending EPA regulations on metal cutting, dry machining is becoming a hot topic of research and investigation both in industry and federal research labs Although the need for dry machining may be apparent, most of the manufacturers still consider dry machining to be impractical and even if possible, very expensive This perception is mainly due to lack of appropriate cutting tools that can withstand intense heat and Built-up-Edge (BUE) formation during dry machining The challenge of heat dissipation without coolant requires a completely different approach to tooling Special tooling utilizing high-performance multi-layer, multi-component, heat resisting, low friction coatings could be a plausible answer to the challenge of dry machining In pursuit of this goal Argonne National Labs has introduced Nano-crystalline near frictionless carbon (NFC) diamond like coatings (DLC), while industrial efforts have led to the introduction of composite coatings such as titanium aluminum nitride (TiAlN), tungsten carbide/carbon (WC/C) and others Although, these coatings are considered to be very promising, they have not been tested either from tribological or from dry machining applications point of view As such a research program in partnership with federal labs and industrial sponsors has started with the goal of exploring the feasibility of dry machining using the newly developed coatings such as Near Frictionless Carbon Coatings (NFC), Titanium Aluminum Nitride (TiAlN), and multi-layer multicomponent nano coatings such as TiAlCrYN and TiAlN/YN Although various coatings are under investigation as part of the overall dry machinability program, this extended abstract deals with a systematic investigation of dry machinability of Aluminum 6061 and 2024 using uncoated carbide, TiN coated carbide, and TiAlN coated carbide inserts Central Composite Design (CCD) is used to study the effect of speed, feed, depth of cut, workpiece material, and cutting tool material on the resulting forces, surface finish, temperature, chip morphology and tool wear Each of the machining responses is measured and compared under 15 different machining conditions Results from CCD experiments have been used to develop linear and logarithmic models for forces (Fx, Fy, Fz, & Fr) surface finish (Ra), and temperature Furthermore, chip morphology and tool wear have also been compared From the comparison of forces, surface finish, temperature, chip morphology, tool wear and the corresponding statistical models, it is clear that in general TiAlN results in lower forces, better surface finish, greater fragmented chips, and lesser tool wearCopyright © 2005 by ASME

3D topography for environmentally friendly machined surfaces

Abstract: Nowadays more and more scientific paper deals with drilling. In recent years there have been limited changes to the drill design but considerable improvements have been made in the selection of drill materials, drill coatings, flute design and the cutting fluid guiding methods. All of these improvements have been introduced to improve the surface finish of the drilled hole, reduce the energy during drilling process and to reduce ecological damage to the cutting fluids, which carry away heat and debris from the cutting zone. The paper briefly describes the development of surface characterization to its current 3D capability. It shows how selected parameters can assist with drill process analysis and how this can be supported through the introduction of the planned new ISO International Standard for 3D surface characterization. The paper is supported by a sample-drilling test to demonstrate the power of the proposed analysis.

Tribological and Thermal Effects of Cutting Fluid Application in Machining With Coated and Grooved Cutting Tools

Abstract: The use of Cutting Fluids (CFs) in machining operations is being increasingly questioned in recent years for environmental and economic reasons, leading to efforts in promoting dry, as well as minimal quantity of lubricant (MQL), machining. However, the tribological effectiveness and thermal aspects of CF action at modern cutting conditions, which not only involve relatively high cutting speeds but also advanced tool coatings and chip-breaking geometric features, need better understanding. This paper presents an experimental investigation into the effects of different CF application methods on various machining performance measures while cutting with commercially available flat-faced, as well as grooved, uncoated and coated cemented tungsten carbide tools. CF effects under dry, flood, and MQL conditions, were gauged through their influence on cutting forces, tool temperatures, tool-chip interfacial contact, and chip morphology during machining of AISI 1045 steel. The results show new trends on the individual cooling and lubricating effects of CF application methods, and the effects of their interactions with the tool coatings and the presence/absence of chip-breaking grooves.Copyright © 2005 by ASME

Apparatus for cleaning water-soluble cutting fluid and method for cleaning water-soluble cutting fluid

Abstract: PROBLEM TO BE SOLVED: To provide an apparatus and a method for cleaning a water-soluble cutting fluid to prevent the generation of foul smell by the efficient sterilization of microorganisms in the water-soluble cutting fluid and sufficiently cleaning the water-soluble cutting fluid to prolong its life. SOLUTION: The cleaning apparatus 1 is provided with a cleaning tank 3 composed of a plurality of tanks 17a-17d successively receiving the water-soluble cutting fluid, a skim removing means (oil skimmer 4) to remove the skim on the water-soluble cutting fluid in a skim-collecting tank 17b among the multiple tanks, and an ozone aeration means 5 to introduce ozone into the water-soluble cutting fluid in the 1st aeration tank 17c placed at the downstream side of the skim collecting tank among the multiple tanks. Preferably, the apparatus is further provided with a cutting fluid supplying means 2 to recover the water-soluble cutting fluid from a cutting fluid tank 8 of a machine tool and supply the fluid to the cleaning tank after filtration. COPYRIGHT: (C)2005,JPO&NCIPI

Cutting fluid and cutting fluid supply apparatus

Abstract: PROBLEM TO BE SOLVED: To provide a cutting fluid which, without using a surfactant and an emulsifier that are harmful to a human body and the environment, has an oil dispersed or emulsified in water; and to provide a cutting fluid supply apparatus which produces the cutting fluid, can suppress its decay without use of a bactericide and permits circulating/reusing the cutting fluid over a long period of time. SOLUTION: The apparatus is equipped with a cutting fluid producing means 3 which produces, without using the surfactant or emulsifier but using an ultrasound oscillator 15, the cutting fluid 2 having the oil dispersed or emulsified in water; a storing means 4 which stores the fluid 2 produced by the means 3; a supplying means which supplies the fluid 2 stored in the means 4 to a cutting portion of a machine tool 5; and a cutting fluid returning means 7 which returns the fluid 2 supplied by the supplying means to the cutting portion of the machine tool 5, to the means 4. COPYRIGHT: (C)2005,JPO&NCIPI

Possibility of ultra-precision cutting of titanium alloy with diamond tool

Abstract: Machine tool: Ultra-precision lathe ULC-100A Toshiba Machine CO., LTD Cutting tool: Single crystal diamond tool Nose radius: 4 mm Rake angle: 0 deg Relief angle: 7 deg Workpiece material: β titanium alloy (Ti-22V-4Al) Cutting fluid: Water-immiscible type Cutting conditions Cutting speed: V = 57-66 m/min Depth of cut: d = 1 μm Feed rate: f = 50 μm/rev Cutting length: L = 0 21,000 m Tool stage Diamond tool

Lubricant oil composition

Abstract: PROBLEM TO BE SOLVED: To provide a lubricant oil composition capable of achieving the whole of stick-slip preventing properties, friction characteristics and separability from water-soluble cutting fluid in high level and in good balance. SOLUTION: The lubricant oil composition contains at least one kind of a base oil selected from a mineral oil, an oil and fat and a synthetic oil, an acid phosphate ester and a 12-16C saturated fatty acid. COPYRIGHT: (C)2005,JPO&NCIPI

Cutting tool with oil hole and cutting method

Abstract: PROBLEM TO BE SOLVED: To spray a cutting medium, in particular a mist or a minimal lubricant (MQL), correctly to a predetermined position and also enable a sufficient amount of cutting fluid to be applied. SOLUTION: A cutting tool with oil holes of the invention includes a cutting edge (3a), an aperture (7d) for spraying the cutting medium, and oil holes (5, 6 and 7c) for supplying the externally supplied cutting medium to the aperture (7d). A hole formed on the aperture (7d) is directed frontward of a face of the cutting edge (3a) from a line connecting the aperture (7d) with the edge (3a). COPYRIGHT: (C)2005,JPO&NCIPI

Analysis of Cutting Fluid Atomization and Environmental Impact through Spin-Off Mechanism in Turning Operation for Environmentally Conscious Machining(II)

Abstract: This paper presents the experimental results to verify the atomization characteristics and environmental impact of cutting fluid. Even though cutting fluid improves the productivity through the cooling and lubricating effects, environmental impact due to cutting fluid usage is also increased on factory shop floor. Cutting fluid's aerosol via atomization process can generate human health risk such as lung cancer and skin diseases. Experimental results show that the generated fine aerosol of which particle size less than 10 micron appears near working zone under typical operation conditions. The aerosol concentration also exceeds NIOSH regulations. This research can be provided as a basis of environmental impact analysis for environmental consciousness.

Cutting liquid filtering device

Abstract: The utility model discloses a cutting liquid filtering device, comprising a dirty liquid box, a clean liquid box and a clapboard which is arranged between the dirty liquid box and the clean liquid box. The upper part of the dirty liquid box and the lower part of the dirty box are respectively provided with a driving shaft and an axle. One end of the driving shaft has a motor, and the axle is provided with a filter tube. Sprockets are respectively arranged on the driving shaft and the two sides of the filter tube. Two pairs of sprockets are wound by chains, and a plurality of scrapers are arranged between two chains to compose a conveyer belt. A cutting fluid inlet and a cutting fluid outlet are arranged on the side walls of the dirty liquid box, and the upper end of the bottom panel is connected with the lower edge of the cutting fluid outlet. The filter tube contains two regular polygon flanges whose corresponding edges all have plate-shaped filter units. Adjacent filter units are connected in the state of seal, and each filter unit and the corresponding edges of the two regular polygon flanges are connected in the state of seal. The cutting liquid filtering device has the advantages of low repair cost, easy repair and the use scope is not limited. The cutting liquid filtering device is suitable for the cutting process device, like a cutting machine tool, to filter the cutting fluid when the workpiece is cut.

Estudio mediante SEM/EDS del taladrado en seco de la aleación Ti-6Al-4V

Abstract: This paper is focused on dry drilling of Ti6Al4V. In absence of cutting fluid, high temperatures are reached. Two different cutting conditions are studied in order to analyze the influence of temperature. In first condition, tests with no pause between drilled holes were carried out. In second condition, tests were performed cooling the tool with air between consecutively holes. Tool wear was studied with optical microscope and SEM-EDS techniques. he quality of machined holes was estimated in terms of optical inspection. Significantly differences in tool wear evolution were observed between both cutting conditions analysed.

Method for supplying cutting fluid at plane face grinding

Abstract: FIELD: machine engineering, possibly planar face grinding by means of cylinder or cone wheel in metal working plants ^ SUBSTANCE: method comprises steps of supplying cutting fluid onto inner surface of wheel through circular multi-duct nozzle; applying onto outer surface of wheel coating easily collapsible at grinding; transporting cutting fluid to grinding zone by filtering it along pores of wheel and in the form of liquid films created on inner and working surfaces of wheel It provides filling of wheel pores with cutting fluid in grinding zone ^ EFFECT: enhanced grinding conditions, improved quality and efficiency of grinding ^ 3 dwg

절삭유 필터링에 따른 엔드밀 가공면 입자 임베딩 현상에 관한 연구

Abstract: With development of high speed and accuracy machining, micro-chips are formed in machining process and the broken particles are circulated with the cutting fluid. The surface roughness and accuracy of part are deteriorated because metal particles included in the cutting fluid are embedded on machined surface. In this study, the influences of particles for the machined surface according to filtering degrees are evaluated and embedding mechanism is suggested.

End Milling of Carbon Steel Using Electrolyzed Reduced Water

Abstract: This paper describes development of end milling of carbon steel by electrolyzed reduced water of dilute sodium chloride solution, instead of conventional cutting with cutting fluid which is not environmentally consciousness. First, experimental equipments were built with a machining center, cutting fluid supply system made from the bath pump, temperature sensor and temperature recorder etc., and end milling processing of carbon steel was performed using electrolyzed reduced water of dilute sodium chloride solution and conventional cutting fluid respectively. Next, measured surface roughness, evaluated surface deterioration layer, temperature change of work piece and wear state of end milling. As the results of all evaluations above-mentioned, there is no difference between the end milling process using electrolyzed reduced water and that of conventional using cutting fluid. It is supposed electrolyzed reduced water instead of cutting fluid is environmentally consciousness process.