A State of the Art on Sustainable Metal Working Fluids in Machining Applications

Abstract

Metalworking fluids (MWFs) play a crucial role in machining processes by lubricating and cooling cutting tools, reducing friction, and improving overall machining efficiency. These fluids can be classified into various types, including cutting oils, water-based fluids, and semi-synthetic or synthetic fluids. Cutting oils are often mineral-based, providing excellent lubrication in heavy-duty applications. Water-based fluids, on the other hand, are more environmentally friendly and commonly used in light to moderate machining operations. Semi-synthetic and synthetic fluids offer a balance between performance and eco-friendliness, incorporating additives to enhance their properties. Proper selection and management of MWFs are essential for optimizing tool life, surface finish, and overall productivity in metal machining applications. Research has shown that the cost of cutting fluid in machining constitutes 17% of the total production cost. In the same research, it was stated that the cutting tool cost was around 4%. This review provides an overview of the current advancements in sustainable MWFs within machining applications. It explores state-of-the-art technologies, formulations, and practices aimed at minimizing environmental impact while maintaining optimal performance in metalworking processes. The review encompasses eco-friendly additives, recycling methods, and emerging trends in the development of MWFs, emphasizing the importance of sustainable practices in the manufacturing industry.