Cooling ability of cutting fluids and measurement of the chip‐tool interface temperatures

Abstract

Many machining researches are focused on cutting tools mainly due to the wear developed as a result of high temperatures generated that accelerate thermally related wear mechanisms, consequently reducing tool life. Cutting fluids are used in machining operations to minimize cutting temperature although there is no available indicator of their cooling ability. In this study, a method to determine the cooling ability of cutting fluids is proposed. A thermocouple technique was used to verify the chip‐tool interface temperature of various cutting fluids during turning operation. The method consists of measuring the temperature drop from 300°C up to room temperature after heating a standardised AISI 8640 workpiece and fixing it to the chuck of a lathe and with a constant spindle speed of 150 rpm the cutting fluid was applied to a specific point. The temperature was measured and registered by an infrared thermosensor with the aid of an AC/DC data acquisition board and a PC. The convective heat exchange coefficient, h, was determined and used to classify the cooling ability of the cutting fluids. The machining tests showed that the application of the fluid with better cooling ability will not always guarantee lower chip‐tool interface temperature.

Understanding the tool wear mechanism during thermally assisted machining Ti-6Al-4V

“…This has traditionally resulted in better heat management at the tool/chip interface using various technologies that incorporate new synthetic coolants, high pressure coolants, cryogenic coolants, minimum quantity lubrication (MQL), steam coolants, compressed gas coolants or hybrid combinations [1][2][3][4][5][6][7][8][9]. Such technologies are reported to extract more heat from the cutting zone and offer better tool life than that achievable using flood coolant.…”

“…Note that PCD tooling was used in this case, not carbide tooling 2. In this context, adhesive or attrition wear is considered to be diffusion related because the adhering material initially bonds with the tool (e.g.…”

Selection of cutting-fluids using a novel decision-making method: preference selection index method

“…Ozcelika et al (2011) investigated the performance of dry and wet cutting during end milling of AISI 316 stainless steel. Sales et al (2002) proposed a method for determining the cooling ability of CFs. Kuram et al (2013) investigated the performances of vegetable-based CFs by comparing tool life, surface roughness and cutting force during end milling of AISI 304 stainless steel.…”

Ti6Al4V Titanium Alloy End Milling with Minimum Quantity of Fluid Technique Use

“…High costs spent for the treatment and reuse of saturated fluids and wash and reuse of chips due to its chemical contamination caused by fluid and additives non-biodegradables [5]. The use of MQF technique, when impractical cutting without lubrication application, brings great contribution in sustainable terms, given the huge volume of titanium Ti6Al4V milled in the aerospace and aviation industries, among others.…”

“…Sales et al [5] studied the cooling capacity and lubrication of some cutting fluids used in machining operations. The results showed that the cooling capacity of these fluids was in increasing order of efficiency: synthetic oil 1, pure water, synthetic oil 2, emulsion in water, neat oil and cutting without lubrication, respectively.…”