Metalworking fluids play a significant role in machining operations and have a substantial impact on tool life, shop productivity, and the quality of the workpiece. The results presented in this article show the influence of the properties of the metalworking fluids and the supply system on the workpiece quality in cutting and grinding processes. Chemical, physical, and tribological aspects have an impact on the properties of the generated surface. For the assessment of cooling effectiveness, a special test rig for the investigation of the coolant supply system in a grinding process is presented. Another approach to investigate the effectiveness and efficiency of the cooling and lubrication system during grinding is to monitor the temperatures and forces by a wheel-based measurement using telemetric data transmission. A further important aspect of water-soluble metalworking fluids is the influence of microbial effects on working results in machining. Microbial degradation leads to drastic changes in the physical and chemical properties of the metalworking fluid during service life. Besides the demands on the efficiency and economy of cutting processes, their environmental friendliness becomes a crucial issue itself. Therefore, an example for a holistic view on the environmental impacts of machining processes and the application of metalworking fluids is given.
The chip removal process in grinding is characterized by intensive friction and plastic deformation leading to the risk of thermal damage of the surface-layer of the machined part. Thus productive and reliable grinding processes need effective monitoring. The difficult to access contact zone between the grinding wheel and the workpiece led to extensive research work on the temperature measurement in the grinding arc. In order to develop a tool integrated temperature monitoring system a new approach was undertaken which makes use of the measurement of infrared-radiation to monitor the temperatures in the grinding arc. The presented research work shows promising results suitable for an industrial applicable system for temperature measurement in grinding. The optical transmission of the infrared temperature information in combination with a fast detecting infrared sensor bares the potential to establish a highly miniaturized measuring system which is easy to integrate in any grinding wheel at comparably low production costs.
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