An experimental study on the tribological effects of targetted cutting fluid combinations on surface integrity of machined AISI 1045 steel

Himabindu Nunna
2012
In order to enable sustainable manufacturing, the indiscriminate use of cutting fluids in modern machining has to be tackled, given its environmental and economic impacts. A possible solution is the recent entrance of dry and near dry minimal quantity cooling and lubrication (MQC/L) machining. In order to evaluate the effectiveness and performance of MQC/L, however, further studies need to be done. The three major functions of cutting fluids are to perform cooling, lubrication, and chip removal
more » ... n, and chip removal from the cutting zone. The main objective of this work is to understand how the tribological aspects (cutting forces, chip flow, tool-chip contact area), chip morphology, and surface roughness and surface integrity (residual stresses) are influenced by i) the application of different cutting fluid combinations in minimal quantities ii) the direction of application of the cutting fluid in the facing of AISI 1045 steel using an uncoated flat-faced carbide tool. A Minimal Quantity Cutting Fluid (MQCF) dispensing system was tested and implemented to evaluate the effects of differing fluid dispensing rates and target directions. It was found that the effects of targeted cutting fluid combinations on the tribological aspects were significant when compared to dry machining, although the variation in the tribological aspects was marginal amongst the different cutting fluid combinations. In contrast, directing the coolant on the flank face of the tool revealed some interesting results. Compressive residual stresses were observed when coolant was 9.
doi:10.26053/0h-zcjq-z7g0 fatcat:kbzotp7ec5h4bfvekagonrzs6e