Cutting Fluids

SOURCES OF HEAT GENERATION

 Wear Mechanisms in Metal Cutting
Wear by plastic shear: work hardening at inner surface of chip due to coolant
&conductivity of tool material

Diffusion wear: Wear from solid-state diffusion from the tool materials to the
workpiece at high temperature and intimate contact at the interface between the chip
and the rake face.

Adhesive wear /Attrition wear : The tool and the chip weld together at local
asperities, and wear occurs by the fracture of the welded junctions( built up edge).

Abrasive wear : As a result of hard particles on the underside of the chip abrading the
tool face by mechanical action as the chip passes over the rake face.

Fatigue wear: Cyclic tension &compression

Electrochemical effect:

Oxidation effect:

Chemical decomposition:
 Tool Wear
Forms
- crater wear
- flank wear
- chipping
Causes
- abrasion
- adhesion
- diffusion
- plastic deformation
 Crater Wear and Flank Wear

Crater wear Adhesion, Diffusion etc.

Abrasion,Adhesion,Shear etc.

Flank wear
Locations and Types of wear
Tool wear as a function of cutting time .Flank wear (FW) is used here as the measure of
tool wear. Crater wear follows a similar growth curve
Effect of cutting speed on tool flank wear (FW) for three cutting speeds, using a tool
life criterion of 0.50 mm flank wear
 KT
KB
Two main types of wear in cutting tool:
1) Flank wear is the development of wear land on the tool due to abrasive rubbing between the
tool flank and the newly generated surface.
2) Crater wear is the formation of a circular crater in the rake face of the tool, as a result of
diffusion wear due to high temperature developed at the interface between the chip and the
rake face of the tool.
The predominant wear process depends on cutting speed.
• Flank wear dominates at lower Speeds
• Crater wear dominates at higher speed
Factors influencing crater wear are
1. The temperature at the tool–chip interface
2. The chemical affinity between the tool and workpiece materials
Diffusion rate increases with increasing temperature, crater wear increases as temperature
increases
Location of the max depth of crater wear, KT, coincides with the location of the max
temperature at the tool–chip interface
Nose wear is the rounding of a sharp tool due to mechanical and thermal effects
It dulls the tool, affects chip formation and causes rubbing of the tool over the workpiece
Tools also may undergo plastic deformation because of temperature rises in the cutting zone
Tools may undergo chipping, where small fragment from the cutting edge of the tool breaks
away
Chipping may occur in a region of the tool where a small crack already exists
Main causes of chipping: Impact, Thermal stresses, Localized cooling, Chatter,
Excessive cratering &flank wear.
The higher temperatures that occur at high cutting speeds which results in increased tool wear
 Flank wear Crater wear

Chipped cutting edge Thermal cracking on rake face

Built-up edge; Catastrophic failure.

Crater wear, and flank wear on a cemented carbide tool, as seen through a toolmaker's microscope
Types of Wear seen in Cutting Tools
Abrasion &Chemical Reaction
 Taylor Tool Life Equation

This relationship is credited to F. W. Taylor (~1900)

where v = cutting speed; T = tool life; and n and C are parameters that
depend on feed, depth of cut, work material, tooling material, and the
tool life criterion used
• n is the slope of the plot
• C is the intercept on the speed axis
 Taylor Tool Life Equation
n
VT  C
n x y
VT d f  C


Natural log‑log plot of cutting speed vs tool life
 Typical Values of n and C in
Taylor Tool Life Equation
Tool material n C (m/min)
High speed steel:
Non-steel work 0.125 120 .
Steel work 0.125 70 .
Cemented carbide
Non-steel work 0.25 900 .
Steel work 0.25 500 .
Ceramic
Steel work 0.6 3000 .
Tool-life Curves
 Machiinabiilliity
Definition: The ability of a material to be machined.
Machinability depends of a number of factors:
1) Hardness – soft materials are easily sheared and require low cutting forces.
2) Surface texture – how easy it is to produce the required surface finish.
Materials with high work hardening exponent tend to form built-up edge (BUE).
3) The maximum rate of metal removal – allow low cycle times.
4) Tool life – abrasive particles can increase tool wear.
5) Chip formation – uniform chips suggest good mach inability.
Machinability is defined in terms of:
1. Surface finish and surface integrity
2. Tool life
3. Force and power required
4. The level of difficulty in chip control
Good machinability indicates good surface finish and surface integrity, a long tool life, and
low force and power requirements
Machinability ratings (indexes) are available for each type of material and its condition
If a carbon steel is too ductile, chip formation can produce built-up edge, leading to poor
surface finish
If too hard, it can cause abrasive wear of the tool because of the presence of carbides in the
steel
In leaded steels, a high percentage of lead solidifies at the tips of manganese sulfide inclusions
 Presence of aluminum and silicon is harmful, as it combine with oxygen to form aluminum
oxide and silicates, which are hard and abrasive. Thus tool wear increases and
machinability reduces.

To improve machinability
• Change the microstructure of the materials. Soft particles are often deliberately
added to improve machinability.
• Reducing the cutting temperature by using cutting fluid – can effectively act as coolant
and lubricant.
Maximum tool surface temperature remains the same but the volume of the tool that reached
the high temperature is reduced.
• Control surface texture – reduce the formation of built-up edge.
• Increase rate of material removal – modern cutting machines, Effect of coolant on tool.
 Cutting Fluid Functions
• Cutting fluids can be classified according to
function:
– Coolants - designed to reduce effects of heat in
machining
– Lubricants - designed to reduce tool‑chip and
tool‑work friction
 Lubricants
• Usually oil‑based fluids
• Most effective at lower cutting speeds
• Also reduces temperature in the operation

Coolants
Water used as base in coolant‑type cutting fluids

Most effective at high cutting speeds where heat

generation and high temperatures are problems

Most effective on tool materials that are most

susceptible to temperature failures (e.g., HSS)
 Cutting Fluids
Effects
Coolant,lubricant,flushes chips, reduces oxidation of heated surfaces
Types:
Cutting oils, emulsified oils, chemical fluids
Function of Cutting Fluids
•It is used to cool the cutting tool and work piece
•It lubricates the cutting tool and thus reduces the co-efficient of friction between tool and work.
•It improves the surface finish as stated earlier.
•It causes the chips to break up into small parts.
•It protects the finished surface from corrosion
•It washes away the chips from the tool. It prevents the tool from fouling.
•It prevents corrosion of work and machine

Properties of Cutting Fluids

•It should have good lubricant properties
•High heat absorbing capacity
•It should have A high specific heat, high heat conductivity and high film co-efficient.
•High flash point
•It should be odorless
•It should be non-corrosive to work and tool.
•It should have low viscosity to permit free flow of the liquid.
Cuttiing flluiids
• The cutting fluids are designed to ameliorate the effects of high
local temperatures and high friction at the chip-tool interface.
Primary functions of cutting fluid :
• To decrease friction and wear.
• To reduce temperature generation
in the cutting area.
• To wash away the chips from the
cutting area.
• To protect the newly machined
surface against corrosion.
Also, cutting fluids help to
• Increase tool life,
• Improve surface finish
• Reduce cutting force
Cutting fluid used in machining
• Reduce power consumption
• Reduce thermal distortion of the
workpiece.