<p>The grooving and parting operations are among the many machining operations that can benefit from cutting conditions and cutting fluid optimization. Optimizing cutting speed, feed rate, and cutting fluid application based on the cut material can increase the grooving tool’s life. Most academic and industry work focuses on optimizing the cutting tool design and cutting conditions such as cutting speed and feed rate. Most grooving tools are used with flood-cutting fluid to reduce the cutting temperatures, remove chips, and act as a lubricant. There is a lack of comprehensive understanding of the role of cutting fluid and its application method in the grooving and parting industries. In this work, cutting fluid application on the cutting performance metrics such as surface roughness, chip formation, and cutting-edge wear were studied. The study also focuses on the chip formation and cutting temperatures generated while cutting with and without cutting fluid application. A flood-cutting fluid application (recommended for the workpiece material), varying amounts, and compositions of the minimum quantity cutting fluid applications were studied along with dry (or no cutting fluid application) cutting. The Saw Blade Lube System™ by UNIST was the MQL system used in this study, and the cutting fluid was used as recommended by the manufacturers. &nbsp;Three different workpiece materials aluminum, low alloy steel, and stainless steel, were used. A coated cemented carbide grooving tool was used as the cutting tool. In general, the grooving tool uses a chip breaker to improve the cutting process through reduced cutting temperatures and cutting forces. The effect of targeting the cutting fluid onto the chip breaker is also investigated better to understand the sustainable solution’s effect on grooving performance. The results show that the minimum quantity cutting fluid applications positively influenced the cutting performance. Mainly, targeted cutting fluid application improved the surface roughness and the chip formation. Similar results were observed in other machining operations. Flood and dry conditions caused severe tooth damage compared to the other experimental conditions. The effect of using a targeted fluid effectively reduced the cutting temperatures, thereby affecting the chip formation and surface generation. Flood fluid application in general, reduced the cutting temperatures along the primary shear zone, thereby increasing the cutting forces. While the dry cutting condition increases the cutting temperatures, it negatively affects (grooving) tool wear. With the targeted cutting fluid application, the cutting temperatures are optimized to increase grooving performance. This road map can be used to improve the grooving tool life, reduce the cutting fluid expenditure, and improve the cut-surface roughness.</p>

Effects of Sustainable Cutting Fluid Solution on Metal Machining With Grooving Tools

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

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