Experimental Analysis for the Use of Sodium Dodecyl Sulfate as a Soluble Metal Cutting Fluid for Micromachining with Electroless-Plated Micropencil Grinding Tools

Abstract

Abstract:Microgrinding with micropencil grinding tools (MPGTs) is a flexible and economic process to machine microstructures in hard and brittle materials. In macrogrinding, cooling and lubrication are done with metal cutting fluids; their application and influence is well researched. Although it can be expected that metal cutting fluids also play a decisive role in microgrinding, systematic investigations can hardly be found. A metal cutting fluid capable of wetting the machining process, containing quantities as small as 0.02% of the water-soluble fluid sodium dodecyl sulfate was tested in microgrinding experiments with MPGTs (diameter~50 µm; abrasive grit size 2-4 µm). The workpiece material was hardened 16MnCr5.

Identification of new indicators for recognition of cutting grains and wear of the grinding wheel based on image recogntion

“…The manufacture of cutting tools [2][3][4][5][6] and grinding of helical grooves [7] from modern tool materials is critically important for the production of high quality parts. Active depth grinding technology is one of the most efficient ways to manufacture tool structures and machine parts from hard and brittle materials with high surface quality and dimensional accuracy [8][9][10][11][12]. For effective removal of material by an abrasive material, a high degree of cutting ability of the edges is required, which depends on the concentration of the abrasive material in the surface layer, its height, size and uniformity of distribution [13,14].…”

A new approach of modeling micromachining parts with a shaped generatrix by image processing of tool's cutting surface

“…Based on their models, surface roughness, grinding forces and temperature can be predicted. However, all the above formulas are limited to taking into account only the average value of the undeformed chip thickness without taking into account its non-uniformity, which reduces the predicted accuracy [25][26][27]. Therefore, it is necessary to investigate the characteristics of the undeformed chip thickness distribution in accordance with the actual topology of the grinding wheels, which, as justified above, can differ greatly from the theoretical ideal models due to the continuous operation of the wheel and its various technical conditions [28][29][30].…”

Submerged micro grinding: a metalworking fluid application study

“…The abrasive layer of utilized MPGTs was clogged with steel adhesions whenever dry machining was done. Adhesions have a strong bond with the abrasive layer; if removed, a portion of the abrasive layer is also detached off its base body [15]. In micro milling, adhesions come in the form of build-up edges that occur on the cutting edges of micro end mills when machining ductile metallic workpieces [16].…”

“…This MWF supply method was introduced to reduce harm to the environment [18]. Of course, for a micro machining process, 50 ml/h can be considered a flood supply of MWF when compared with conventional scales [15]. One of the most widespread practices is using an MQL supplying method in combination with nanofluids-a water-or oil-based fluid that usually contains a surfactant and nanoparticles made out of graphite, aluminum oxide, or diamond to increase the thermal conductivity of the MWF via the ball bearing effect [19].…”

“…This MWF was compared with dry machining and experiments with distilled water as a coolant. The experiments conducted with SDS were the only ones where the tool managed to machine the assigned cutting path of 0.5 mm [15]; however, the tools suffered from high amounts of adhesions and flattened abrasive grits, indicating high process temperatures [21]. In a follow-up study, an SDS solution, isopropanol, and the commercially available synthetic oil DiaMond 80 were used via MQL in a micro milling experiment.…”