Journal of Cleaner Production 42 (2013) 159e166

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Journal of Cleaner Production

journal homepage: www.elsevier.com/locate/jclepro

Optimization of cutting fluids and cutting parameters during end milling by using
D-optimal design of experiments
Emel Kuram a, Babur Ozcelik a, *, Mahmut Bayramoglu b, Erhan Demirbas c, Bilgin Tolga Simsek a
a
Department of Mechanical Engineering, Gebze Institute of Technology, 41400 Gebze-Kocaeli, Turkey
b
Department of Chemical Engineering, Gebze Institute of Technology, 41400 Gebze-Kocaeli, Turkey
c
Department of Chemistry, Gebze Institute of Technology, 41400 Gebze-Kocaeli, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: The use of synthetic cutting fluids is nowadays limited due to the adverse effects such as health of the
Received 5 August 2012 operator, environmental and economic reasons. In order to diminish these negative effects, bio-based
Received in revised form cutting fluids are used. Bio-based or vegetable based cutting fluid is considered environmentally
31 October 2012
friendly and sustainable. Vegetable based cutting fluids have some characteristics such as biodegrad-
Accepted 2 November 2012
Available online 15 November 2012
ability, less toxicity and renewability. This study deals with the assessment of vegetable based cutting
fluids for end milling. For this purpose, effects of cutting fluid types are investigated as a function of three
milling factors (cutting speed, depth of cut and feed rate) on process responses (specific energy, tool life
Keywords:
Milling
and surface roughness). D-optimal method is conducted to develop mathematical models for process
Optimization responses. Variance analysis shows that specific energy, surface roughness and tool life can be predicted
Cutting fluids effectively with quadratic models. Furthermore, mono and multi objective optimization studies are
D-optimal conducted using specific energy, surface roughness and tool life as primary or secondary objectives. From
Specific energy results of the optimization, various conclusions are drawn about effects of the milling parameters and the
Surface roughness cutting fluid types on the milling performance criteria. The most appropriate cutting fluid during milling
Tool life of AISI 304 material is selected in accordance with energy, tool life and surface roughness.
Ó 2012 Elsevier Ltd. All rights reserved.

1. Introduction machining. Fratila and Caizar (2011) used near-dry techniques

The machinability of AISI 304 is difficult and high cutting force,
high tool wear and poor surface quality can be observed during
machining of this material since it has high strength, high ductility
and low thermal conductivity. Cutting fluids are utilized to eliminate
these adverse effects. Today a wide variety of cutting fluids (soluble
oils, straight oils, synthetic and semi-synthetic fluids) are commer-
cially available. But, the use of cutting fluids is being questioned due
to the health and environmental impacts (Shashidhara and Jayaram,
2010; Tawakoli et al., 2011) and usage of large amount of cutting
fluids during machining is considered one of the main environ-
mental pollution sources (Fratila, 2009). Marksberry (2007) used
a micro-flood technology for minimizing the use of cutting fluid
during machining which was atomization-less and occupational
friendly. Sanchez et al. (2010) investigated a new approach based on
the use of a hybrid minimum quantity of lubrication (MQL) e low
temperature CO2 systems to the elimination of cutting fluids in
* Corresponding author.
E-mail address: ozcelik@gyte.edu.tr (B. Ozcelik).
during milling process to meet cleaner manufacturing. Zhang et al.
(2012) combined the advantages of the cryogenic air and MQL
method in order to meet the demands for environmental-friendly
machining processes. Cutting fluids are contaminated with metal
particles and tramp oil during their life cycle and this contamination
diminishes the effectiveness of cutting fluids. When cutting fluids
lose their quality, the disposal of them is mandatory. Waste disposal
is expensive and affects the environment negatively. In order to
minimize the adverse environmental effects with the use of cutting
fluids, the hazardous substances in their formulations have to be
eliminated or diminished to the acceptable value. In addition,
petroleum based cutting fluids can be replaced with bio-based
cutting fluids (Ozcelik et al., 2011a, 2011b). Bio-based cutting fluids
reduce the health risks as compared to the petroleum based cutting
fluids and have higher biodegradability. They have also good lubri-
cation capability as compared to others (John et al., 2004). Vegetable
based cutting fluids can be considered environmentally friendly
because these types of fluids are renewable, less toxic and possess
high biodegradability.
Studies about vegetable based cutting fluids (VBCFs) on various
mechanical processes have been focused on drilling, turning,

0959-6526/$ e see front matter Ó 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.jclepro.2012.11.003
160 E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166
tapping and reaming. In these studies tool life, tool wear, force,
torque and surface quality are taken into consideration. The use of
VBCFs in other metal cutting operations has gained more attention
nowadays. Belluco and De Chiffre (2001) investigated the effect of
different lubricants on cutting forces and power. AISI 316L stainless
steel were machined with drilling, core drilling, reaming and
tapping. VBCFs gave equal or better performance than a reference
commercial mineral oil. In another study, Belluco and De Chiffre
(2002) presented the effect of new formulations of vegetable oils
on surface integrity (roughness, microhardness) and part accuracy
in reaming and tapping with AISI 316L. They found that cutting
fluids have a significant effect on surface integrity and part accu-
racy. They also stated that VBCFs resulted in comparable or better
performance than that of mineral oils. Belluco and De Chiffre
(2004) evaluated the performance of six cutting fluids (a
commercial mineral oil, and five VBCFs) in drilling of AISI 316L
stainless steel using conventional HSS-Co tools. Tool life, tool wear,
chip formation and cutting forces were studied as performance
criteria and results showed better with VBCF than that of mineral
cutting fluid because tool life was increased by 177 percent and
thrust force was reduced by 7 percent. Xavior and Adithan (2009)
measured for tool wear and surface roughness as a performance
criterion, and studied performances of coconut and neat cutting
fluids during turning of AISI 304 with carbide tool. Results from
coconut cutting fluid showed a better performance than that of
mineral based cutting fluids. In another study, Xavior and Adithan
(2010) investigated the effect of coconut oil on tooleshim inter-
face temperature and cutting force during turning of AISI 304
material with carbide tool. It was found that coconut oil out-
performed the other cutting fluids (soluble oil and straight cutting
oil). Cetin et al. (2011) investigated the role of extreme pressure
(EP) additive on VBCFs in terms of surface roughness, cutting and
feed forces during turning of AISI 304L with carbide insert tool
using Taguchi’s mixed level parameter design. Sunflower and
canola oils with different ratios of EP additives and commercial
semi-synthetic and mineral cutting fluids were used. Results
showed that VBCFs performed better than the rest. Characteriza-
tions of chemical and physical analyses of VBCFs were presented in
detail by Kuram et al. (2011). They also investigated the perfor-
mance of VBCFs developed from crude and refined sunflower oils
for thrust force and surface roughness during drilling of AISI 304
using Taguchi method. Rahim and Sasahara (2011) used palm oil in
a high speed drilling of Ti-6Al-4V. In this study, synthetic ester
using minimum quantity of lubrication method, air blow and flood
conditions were used. The palm oil and synthetic ester showed
a comparable performance with the flood conditions and palm oil
performed better than synthetic ester on the cutting forces,
temperature, power and specific cutting energy. Kuram et al.
(2012a) investigated the effects of blended VBCFs with EP addi-
tive on tool wear and force components in turning of Al 7075-T6
material. It was concluded that blending of two vegetable oils
(sunflower and canola oils) improved cutting performance.
Considerable amount of energy is consumed for chip formation
during metal cutting process which should be optimized. In rough
milling, high material removal rate (MRR) is important without
enhancement of tool wear. In finish milling the prime objective is
the minimization of surface roughness. Cutting parameters affect
the surface roughness and cost in machining, so the optimization of
these parameters is very important.
The modelling and optimization of machining have been
investigated by various researchers. Various analytical methods are
developed and used for predicting of surface roughness, tool wear
and force in milling (Ozcelik and Bayramoglu, 2006; Razfar et al.,
2011; Zain et al., 2011). Iqbal et al. (2008) studied effect of micro-
structure, cutting speed, radial depth of cut (step over) and
workpiece inclination angle on surface roughness and tool life
under MQL environment using the D-optimal method. Kuram et al.
(2012b) used D-optimal experimental design method to develop
the model equations of surface roughness and machining forces in
turning process. An average error between developed models and
experimental results was found as <7%.
Concepts for sustainable and cleaner production concern on the
formation of products using processes and systems that are non-
polluting and conserving the natural resources (Fratila and Caizar,
2011). It is essential to manufacture products using sustainable
methods and to reach this ecological aim it is mandatory to
determine optimum machining conditions, while increasing tool
life, decreasing surface roughness and consumed energy. This work
focuses on the role of environmentally friendly method (VBCFs) in
milling which includes three main issues: effects of VBCFs on the
tool life, the energy consumed in the milling operation, and
workpiece’s surface roughness. In this paper, D-optimal method is
used to plan the experiments.
2. Experimental design
2.1. Vegetable-based cutting fluids
The efficiency of cutting process is improved by cutting fluids
(CFs). CFs combine two properties, the lubrication of oil and the
cooling of water. It is usually diluted with water in the range of 92e
97% depending on the cutting operations. Although a vegetable
based oil emulsion is environmentally friendly and biodegradable,
there are few references on this emulsion as cutting fluids in the
literature.
This work focuses on the development of vegetable based oil
emulsions that can be utilized in milling operation to replace semi-
synthetic cutting fluids. The general composition of water miscible
VBCFs consists of base oil from refined sunflower oil or canola oil
and a mixture of emulsifier(s). Other components such as corrosion
and rust inhibitors, neutralization agents, lubricating additive (EP),
fungicides, biocides, and foam inhibitors may be added to the
cutting fluid. pH, density, viscosity, flash point and refractive index
are measured to characterize the VBCFs. Characterization of CFs is
given in Table 1. pH values are measured by a pH meter (Hach Lang
HQ 40d) and changed from 8.92 to 9.18. In general, pH values of
cutting fluids vary from 8.5 to 10.0. Too high or too low pH values
can be dangerous to operator and cause some problem in waste
disposal. Density of cutting fluid should be compatible with density
of water. In this work, density of cutting fluids is measured by
a pycnometer and density values are 0.96e0.98 g/ml. Viscosity of
a cutting fluid is also an important parameter and determines the
effectiveness of cutting fluids. Viscosity is measured by a Brookfield
LDV-E viscometer and the viscometer is calibrated with pure water.
Viscosities of the cutting oils and their emulsions are 75e110 and
1.7e4.1 mm2/s. In the machining at high temperature the usability
of cutting fluid is determined by flash point and flash point is
measured with a K16500 rapid flash closed-cup tester. In flash
Table 1
Characterization of vegetable based cutting fluids.
Metal pH Density Viscosity Viscosity, Flash Refractive
cutting (Emulsion 8%) (g/ml) 40
C 40
C (mm2/s) point index
fluida (mm2/s) (Emulsion 8%) (
C)
SCF-II 8.92 0.96 91 4.1 217 1.4775
CCF-II 9.00 0.97 110 3.9 232 1.4770
CSSF 9.18 0.98 75 1.7 235 1.4825
a
SCF-II: sunflower cutting fluid with 8% EP additive; CCF-II: canola cutting fluid
with 8% EP additive; CSSF: Commercial semi-synthetic cutting fluid.
 E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166
point measurement, a sample of the cutting fluid was placed in the
cup and the temperature is increased with time during measure-
ment. The value of the cutting fluids ignited is saved as the flash
point. Flash points of cutting fluids are varied in the range of 217e
235
C. Refractive index is measured by an Abbe refractometer and
values are varied in the range of 1.4770e1.4825. Cutting fluids
utilized in current work are named as follows:
SCF-II: sunflower cutting fluid with 8% EP additive
CCF-II: canola cutting fluid with 8% EP additive
CSSF: Commercial semi-synthetic cutting fluid
EP additives reduce chip welding under high pressures and
improve lubrication function at high temperatures (Stachowiak
and Batchelor, 2005). In current work, sulphur based EP additive
is used. It is reported that sulphur based EP additive might induce
less serious environmental concern such as health, disposal, air
and soil pollution issues than EP additives contained in, for
instance, antimony, iodine or chlorine (Mendes et al., 2006). For
instance, cutting fluids with chlorine based EP additive are
hazardous to human life and to the environment. EP additives
containing chlorine are difficult to dispose of and classified after
use as hazardous waste (Sokovic and Mijanovi c, 2001). Newly
developed VBCFs are environmentally friendly and contain no
harmful substances. These VBCFs also have higher rate of biode-
gradability (>95%) which is the most important aspect of the
environmental compatibility.
2.2. Experimental design
In this study, D-optimal method was used to design the exper-
iments. D-optimal experimental design is response surface based
methodology, used for conducting the design of experiments, the
analysis of variance, and the empirical modelling, and this method
has some advantages compared to other response surface methods.
D-optimal method gives smaller number of experiment with
respect to response surface method and can tackle categorical
factors included in the design of experiment.
Among various experimental design alternatives for second
order models, optimal designs are preferred owing to their
successful applicability to mixed type mixed level factorial exper-
imentation requiring in most situations fewer runs than conven-
tional methods. Various criteria are proposed to search the optimal
plan, among which D-optimality is the most popular one seeking to
maximize determinant of the information matrix, (X’X) providing
the best simultaneous estimate of the model parameters. Here, X is
the design matrix with n rows representing the experiments in the
design and p columns representing the model coefficients. Further
information about D-optimal method can be found in the literature
(Eriksson et al., 2008; Myers et al., 2009). Table 2 presents statistical
results of the D-optimal plan obtained from Design-Expert (trial
version 7.0) statistical package.
Table 2
Statistical results of the D-optimal plan.
Statistics Value
Maximum Prediction Variance 0.921
(at a design point)
Average prediction variance 0.667
Condition number of coefficient 7.42
matrix
Scaled D-optimality Criterion 2.388
Determinant of (X’X)1 1.094E-19
Trace of (X’X)1 2.570
161
The experimental design has three numeric factors (cutting
speed, depth of cut and feed rate) and a categorical (qualitative)
factor such as type of cutting fluid. For the modelling and optimi-
zation purposes, a second order model is chosen, which is suffi-
ciently complicated to approximate the main features of the data.
The experimental planning and the statistical analyses are per-
formed using Design-Expert (trial version 7.0) statistical package.
The full second order model for the case of three numeric factors
(X) and one categorical factor (Z) at three levels is given in the form
of
X
3 3 X
X 3 X
3
Y ¼ b0;k þ bi;k Xi þ bi;j Xi Xj þ bi;i Xi2 (1)
i¼1 i¼1 i¼1 i¼1
isj
where k is the cutting fluid index, i and j refer to numeric factors.
As seen in Eq. (1), the model contains pure linear terms for both
quantitative and qualitative factors, two-term interactions and
second-order terms for only quantitative factors.
The total number of parameters for the second order model is 17.
An experimental plan with 27 experiments is chosen to allocate
four and five degrees of freedom for lack of fit and pure error.
Various algorithms are proposed to find the optimum design. In
the current study, a point exchange algorithm is utilized for this
purpose and the program is restarted ten times to select the
globally optimal design with the lowest determinant value. In the
point exchange algorithm, a random design is created from the
possible design points, called a candidate set. Then new designs are
created by iteratively replacing individual points with the best
replacement available from the candidates and this procedure is
repeated for all design points until no improvements are possible.
The whole procedure is repeated several times for different random
initial designs and the best overall design from all the starts is
selected (Myers et al., 2009). The candidate points used by the
program consist of 8 vertices, 12 centre of edges, 18 interior points
and 1 overall for each level of the categorical factor. Important
statistical indicators of the final plan are as follows: Table 3 shows
the low and high levels of factors which are selected on practical
considerations, while Table 4 shows the D-optimal experimental
plan in term of actual factor values. 1, 2 and 3 in Table 4 represent as
CCF-II, SCF-II and CSSF.
2.3. Machining conditions
The cutting fluids are applied to the tool via two nozzles (Fig. 1).
The coolant flow rate of each nozzle is 10 L/min and held constant
throughout the experiments. Down milling method is employed
owing to some pros such as less tool wear, better surface quality
and less heat. The step over is selected as 10 mm. The length of each
cutting path is 1040 mm.
2.4. Workpiece materials and cutting tools
The tests are conducted on Deckel Maho CNC machine and
experimental set up is showed in Fig. 2. As a workpiece material,
AISI 304 with a chemical composition of 0.032% C, 18.410% Cr,
Table 3
Numeric factor levels.
Factors Low level High level
Cutting speed (m/min) 150 200
Feed rate (mm/rev) 0.20 0.30
Depth of cut (mm) 0.20 0.40
162 E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166

Table 4 0:3
D-optimal experimental design with 27 runs. T ¼ (2)
VVB
Cutting Feed Depth CF type
speed (V) rate (f) of cut where VVB is tool wear rate in mm/min and T is tool life in min. The
(m/min) (mm/rev) (ap) (mm)
maximum flank wear is 0.3 mm in finish milling process.
200.00 0.27 0.20 1
150.00 0.30 0.27 1
200.00 0.30 0.40 1 2.6. Force measurement
150.00 0.20 0.20 1
200.00 0.20 0.30 1
150.00 0.25 0.40 1 The forces generated are measured using Kistler 9257B dyna-
166.67 0.20 0.33 1 mometer which is mounted under the workpiece. Resultant force
150.00 0.30 0.27 1 (total cutting force) is computed using Eq. (3).
150.00 0.20 0.20 1
150.00 0.30 0.20 2 qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
166.67 0.30 0.40 2 Fc ¼ Fx2 þ Fy2 þ Fz2 (3)
200.00 0.20 0.40 2
200.00 0.30 0.20 2 The cutting power utilized for milling is calculated by multi-
175.00 0.20 0.20 2 plying the total cutting force by the cutting speed (Eq. (4)).
150.00 0.20 0.40 2
187.50 0.25 0.30 2
Pc ¼ Fc$v (4)
150.00 0.25 0.30 2
166.67 0.30 0.40 2
166.67 0.30 0.20 3 where Pc is cutting power (W), Fc is force (N) and v is cutting speed
200.00 0.30 0.33 3 (m/s). On the other hand, the specific energy is computed from Eq.
150.00 0.30 0.40 3 (5).
200.00 0.20 0.20 3
183.33 0.20 0.40 3 Pc
150.00 0.20 0.30 3 U ¼ (5)
166.67 0.23 0.20 3 MRR
183.33 0.20 0.40 3
150.00 0.30 0.40 3 where U is specific energy in J/mm3 and MRR is material removal
rate in mm3/s. In machining process most of the environmental
impact stems from the energy consumed. In order to calculate the
energy requirement for material removal, the specific cutting
7.740% Ni, 1.930% Mn, 0.660% Cu, 0.580% Si, 0.373% Mo and Fe energy is often used (Fratila, 2010), therefore in this study specific
balance is utilized. The dimension of workpieces is energy is estimated.
165  104  30 mm. The milling tests are conducted by using
two inserts (Iscar HM90 APKT100304PDRIC908) coupled to
2.7. Surface roughness measurement
16 mm diameter shrink holder. After milling operation, two
inserts being utilized are changed with new inserts. The flank
Surface roughness (Ra) is measured in transverse feed directions
wears of two inserts are measured and the averages of these
using Mitutoyo Surf Test 301. Number of sampling and cut-off
values are used.
length are chosen as 5 and 0.8 mm. The measurement of surface
roughness is repeated three times and average values of these three
2.5. Tool wear measurement measurements are taken into consideration to make further
analysis.
The flank wear is measured with an optical microscope (NIKON
SMZ800) at 50 magnification. The milling process is interrupted
for each experiment after completion and then value of the wear is 3. Results and discussion
measured. Example tool wear result can be seen in Fig. 3. Tool wear
rate is computed by dividing wear by the milling time. Eq. (2) is 3.1. Modelling results
used to calculate the tool life.
Variance analysis conducted on the experimental results
suggests quadratic models for surface roughness, specific energy
and tool life. Table 5 shows the models for surface roughness,
specific energy and tool life. In these models interaction terms are
independent from the cutting fluid type, while linear terms are
dependent on the cutting fluid type. These dependent coefficients
are shown in Table 5 for each type of cutting fluid. Table 6 shows
various statistics about the statistical validity of the models.
Various statistical indicators given in Table 6 can be commented
briefly as follows:

- R2 and Adj R2 values (accounting for the number of predictors

in the models) indicate that the model fits the data well.
Especially, pred R2 is in agreement with adj R2 which supports
prediction power of the model.
- Signal to noise ratio is measured by Adeq precision. Adeq
precisions are greater than 4 for all models which are usually
Fig. 1. Applying of cutting fluids. desirable and these models can be used.
 E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166 163

Fig. 2. Experimental set up.

3.2. Optimization results
In the following sections, firstly, the results of three mono
objective optimization studies are presented, and later various
multi objective optimization results are given and commented
from various perspectives of the end milling including the impact of
the cutting fluid on the operation performance.
3.2.1. Mono objective optimization
Various response models obtained in this study are considered
further for optimization of the end milling operation. These
responses may be used alone in optimization studies as objective
function. This is a constrained optimization problem with both
numerical and categorical variables shown in Eq. (6):
Optimize y ¼ f ðX; ZÞ
cutting fluids. High values of these cutting parameters cause
inevitably very low tool life and high surface roughness.
 The values of the other important responses, tool life and surface
roughness, do not show the similar trends with the minimum
energy values. For examples, CCF-II consumes considerably lower
energy than SCF-II, but gives lower tool life. Furthermore, the
surface roughness values are comparable for CCF-II and SCF-II.
 In conclusion, if the main objective is to minimize the specific
energy, CCF-II should be preferred as the best cutting fluid.
Moreover, if the cost of machining operation is important, the
relative weight of costs of consumed energy and cutting tool in
the total cost will determine the most appropriate cutting fluid.
In such a case, a choice between CCF-II and SCF-II can be
considered. In brief, use of VBCFs can save energy and meet the
demands for cleaner production.
(6)

3.2.1.2. Minimization of the surface roughness. Table 7 presents the

s:t: Li  Xi  Ui i ¼ 1:3 surface roughness minimization results. The following conclusions
are extracted from this table:
Z ¼ CCF  II; SCF  II; CSSF

where L and U are lower and upper bounds of the numerical factors.

3.2.1.1. Minimization of the specific energy. Energy generation is

amaincontributortocarbondioxideemissionsandclimatechange,thus
reducing energy consumption is an essential consideration in sustain-
able manufacturing (Pusavec et al., 2010; Rajemi et al., 2010) and cleaner
production (Hanafi et al., 2012). So in this study minimization of specific
energy is considered and the minimization results are summarized in
Table 7 from which the following conclusions can be drawn:

 Minimum specific energy values considerably depend on the

cutting fluid type; the optimal value obtained with CCF-II
(1.32 J/mm3) is 105% lower than the worst case (2.71 J/mm3)
obtained with SCF-II. Meanwhile, optimum cutting conditions
depend weakly on the cutting fluid type; optimum cutting
conditions are the same for CCF-II and SCF-II. Moreover, the
optimum value of depth of cut (0.3 mm) is the same irre-
spective of the fluid type. In the case of CSSF, optimum feed rate
and cutting speed are 25% and 15% higher than those of other Fig. 3. Example tool wear result.
164 E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166

Table 5
Modelling results for specific energy, surface roughness and tool life.
P
U ¼ b0;k þ 3i ¼ 1 bi;k Xi  5:03*V*f þ 1:06*V*ap  1550:49*f 2 þ 295:34*a2p þ 9:81*V*f 2  1:71*V*a2p
P
Ra ¼ b0;k þ 3i ¼ 1 bi;k Xi þ 0:007*V *f þ 0:005*V *ap  0:21*f *ap þ 7:46*105 *V 2  5:24*f 2 þ 3:52*a2p
P
T ¼ b0;k þ 3i ¼ 1 bi;k Xi þ 0:50*V*f þ 272:78*f 2

Coefficients of linear terms of models

Type of cutting fluid b0,k b1,k b2,k b3,k

Specific energy
CCF-II 71.02 0.484 791.63 183.74
SCF-II 69.63 0.476 791.63 183.74
CSSF 68.08 0.467 791.63 183.74

Surface roughness
CCF-II 2.71 0.029 2.86 2.29
SCF-II 2.67 0.028 2.41 2.90
CSSF 2.57 0.027 2.79 2.99

Tool life
CCF-II 51.22 0.16 219.77 18.00
SCF-II 56.38 0.16 239.01 18.00
CSSF 57.76 0.16 244.02 18.00

 Minimum surface roughness is achieved with CCF-II and the general results can be achieved on the cutting conditions, inde-
worst result belongs to CSSF. Optimum feed rate value is pendent of the fluid type
independent of the cutting fluid type, while other cutting
parameters differ more or less for each cutting fluid type,  To minimize the consumed energy, low cutting speed and feed
affecting strongly the surface quality. rate are required.
 While CCF-II gives minimum surface roughness, its tool life is  To minimize the surface roughness, low feed rate must be
the worst as compared to other cutting fluids. Higher specific selected.
energies obtained with SCF-II and CSSF are due to higher depth  All the cutting parameters must be selected at their low levels
of cut values. Lower cutting speed in the case of CSSF favours to maximize the tool life.
a longer tool life and moderate specific energy when compared
to SCF-II. 3.2.2. Multi objective optimization
 From the above results, if the main goal is to minimize surface The optimization problem may be considered in a more general
roughness, CCF-II should be preferred as a cutting fluid. When context; different objectives may be defined by taken into consid-
the cutting economy is also considered, the most appropriate eration the performance of the process for a multi objective opti-
fluid type would be selected by a compromise between mization; the surface quality of the finished product is usually the
finished surface quality and operating cost. primary objective which is expressed by the surface roughness.
Meanwhile, other objectives reflecting the economy of the process
3.2.1.3. Maximization of the tool life. The maximization result of the may be also considered for a more effective end milling. In this
tool life is presented in Table 7 and the below results can be context, tool related responses such as tool wear and tool life reflect
obtained: the tool cost, while specific energy reflects the electrical energy
cost. These two cost items account for an important part of the
 To maximize the tool life, cutting speed, feed rate and depth of cut direct operating cost.
must be selected as 150 m/min, 0.2 mm/rev and 0.2 mm, respec- A multi objective optimization problem may be defined in
tively.Themaximumtool lifevalues ofCSSFandSCF-IIareofsimilar various ways. In this study, the problem is defined in the context of
magnitude. Surprisingly, the optimum cutting conditions are “implicitly constrained optimization”: One of responses is selected as
independent of the cutting fluid type and they are at their lowest
levels. Table 7
 The fluid type influences also the other response values at the The results of specific energy, surface roughness minimization and tool life
maximization.
same cutting conditions. CCF-II consumes less energy and
performs better in terms of the surface quality. Thus, if the Cutting fluids Cutting Feed rate Depth of Specific Surface Tool life
main goal is to maximize the tool life, CSSF is the preferred fluid speed (mm/rev) cut (mm) energy roughness (min)
(m/min) (J/mm3) (mm)
type. But, this conclusion is not very obvious if the other
responses are also taken into account. Specific energy
CCF-II 150 0.2 0.3 1.3200a 0.3031 3.4770
From the numerical optimizations, it is seen that CCF-II SCF-II 150 0.2 0.3 2.7100 0.2887a 4.7878a
performs globally better than the rest. Moreover, following CSSF 175 0.25 0.3 1.9507 0.3815 1.9027

Surface Roughness
CCF-II 175 0.2 0.208 2.1033a 0.2013a 3.5827
Table 6
SCF-II 169 0.2 0.292 3.2962 0.2630 3.7538
Statistical results for proposed models.
CSSF 165 0.2 0.300 2.4979 0.2935 4.2393a
Response Std. dev. R2 Adj R2 Pred R2 Adeq Tool Life
precision CCF-II 150 0.2 0.2 1.8520a 0.2853a 5.2767
Specific energy 0.093 0.9750 0.9500 0.8625 30.128 SCF-II 150 0.2 0.2 3.2420 0.3286 6.5875
Surface roughness 0.026 0.9605 0.8859 0.7079 12.957 CSSF 150 0.2 0.2 2.7716 0.3597 6.9690a
Tool life 0.70 0.9163 0.8720 0.8070 12.645 a
optimum values of surface roughness, specific energy and tool life.
 E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166 165

Table 8
Multiobjective optimization results.

Cutting fluids Cutting speed (m/min) Feed rate (mm/rev) Depth of cut (mm) Specific energy (J/mm3) Surface roughness (mm) Tool life (min)

Specific energy selected as primary objective function

CCF-II 150 0.2 0.268 1.4057 0.2897 4.0529
SCF-II 150 0.2 0.300 2.7100 0.2887 4.7878
CSSF 170 0.2 0.268 2.6093 0.2999 4.5052

Surface roughness selected as primary objective function

CCF-II 167 0.2 0.212 1.9897 0.2176 4.0067
SCF-II 159 0.2 0.300 2.9845 0.2699 4.2298
CSSF 165 0.2 0.300 2.4979 0.2935 4.2393

Tool life selected as primary objective function

CCF-II 150 0.2 0.200 1.8520 0.2853 5.2767
SCF-II 152 0.2 0.240 2.9806 0.2984 5.7436
CSSF 161 0.2 0.272 2.4728 0.2998 4.9912

primary objective function y to be optimized, while the others are Secondly, the surface roughness is selected as primary objective
used as implicit constraints f: function, while specific energy and tool life are used as the implicit
constraints. These results are given in Table 8 and the following
Optimize y ¼ f ðX; ZÞ (7) conclusions are extracted:

s:t: Li  Xi  Ui i ¼ 1:3  Minimum surface roughness and the worst quality are ob-
tained with CCF-II and CSSF. Optimum feed rate value is
Kj  fj  Hj j ¼ 1:2 independent of cutting fluid type, while other cutting param-
eters differ for each fluid type.
 While CCF-II gives minimum surface roughness, its tool life is
Z ¼ CCF  II; SCF  II; CSSF the worst as compared to the rest of the cutting fluids.
K and H are lower and upper bounds on the implicit constraints  In conclusions, if the primary objective is to minimize surface
which are selected based on mono objective optimization results as roughness, CCF-II should be preferred as a cutting fluid. The
follows: most appropriate fluid type also would be determined by the
operating cost.
U  3 J=mm3 (8)
Finally, tool life is selected as primary objective function, while
specific energy and surface roughness are used as the implicit
Ra  0:3 mm
constraints. The following conclusions are drawn from Table 8:

T  4 min
These constraints are for illustrative purpose which may be
decided with respect to the special application. First, specific
energy is chosen as the primary objective function, while tool life
and surface roughness are used as the implicit constraints. These
results are presented in Table 8. The following conclusions are
depicted from this table:
 Minimum specific energy is obtained with CCF-II and SCF-II
gives the worst result. The optimal specific energy value ob-
tained with CCF-II is 92.78% lower than obtained with SCF-II.
Optimum feed rate value is independent of cutting fluid type.
 While CCF-II gives minimum specific energy, its tool life is the
worst. Higher specific energy obtained with SCF-II is due to
higher depth of cut value with respect to rest of the cutting
fluids.
 The minimum surface roughness values of CCF-II, SCF-II and
CSSF are of similar magnitude.
 The values of the other important responses, specific energy
and tool life, do not show the similar trends. CCF-II consumes
considerably lower energy than that of SCF-II, but gives lower
tool life.
 In conclusion, if the primary objective is to minimize the
specific energy, CCF-II should be preferred as the best cutting
fluid. On the other hand, the proportion of costs of consumed
energy and cutting tool in the total cost will determine the
most appropriate cutting fluid. Under these circumstances,
CCF-II or SCF-II can be used as a cutting fluid.
 Maximum tool life is obtained with SCF-II and CSSF gives
minimum tool life. Optimum feed rate value is independent of
cutting fluid type, while other cutting parameters are depen-
dent of the cutting fluid type.
 While SCF-II gives maximum tool life, its consumed energy is
the highest with respect to the rest of the cutting fluids.
 The magnitudes of minimum surface roughness values of CCF-
II, SCF-II and CSSF are similar.
 The values of the other important responses, specific energy
and tool life, do not show the similar trends. CCF-II consumes
considerably lower energy than SCF-II, but gives lower tool life.
From the multi objective numerical optimizations, it is seen that
CCF-II performs globally better than the rest.
4. Conclusions
In this study, vegetable based cutting fluids are developed to
meet the demands for environmentally friendly machining
processes. Effects of the machining variables (cutting speed, feed
rate and depth of cut) and cutting fluids on the milling of stainless
steel are investigated for the experimental study. D-optimal
experimental design is used to investigate the effect of these vari-
ables on specific energy, surface roughness and tool life. The
following conclusions from mathematical models and mono
objective optimizations are drawn:
The relationship between responses and the variables utilized in
the current work is well represented by the proposed models.
166 E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166
Minimum specific energy considerably depends on the cutting fluid
type. If the main aim is to minimize the specific energy, CCF-II
should be preferred as a cutting fluid because cost of the
machining process is important. The proportion of cost of
consumed energy and cutting tool in total determines the most
appropriate cutting fluid. In such a case, CCF-II or SCF-II can be
selected as a type of cutting fluid. If the main goal is to minimize the
surface roughness, CCF-II should be preferred as a cutting fluid.
When total cost is taken into consideration, a choice between CCF-II
and CSSF can be considered. If the main objective is to maximize
the tool life, CSSF should be preferred as a cutting fluid. On the
other hand, from the multi objective numerical optimizations, it is
seen that CCF-II performs globally better than the others. From
environmental and machining performance points of view, vege-
table based cutting fluids meet the cleaner manufacturing
demands, can improve the machining performance and VBCFs can
be considered as an alternative cutting fluids to semi synthetic
cutting fluids.
Further research study could help to develop for reducing both
environment impact and health issues from the cutting fluids by
improving its formulae and rate of biodegradability. Then attention
have to focus on developing new kinds of vegetable based cutting
fluids for variety of machining operations (milling, drilling, tapping,
reaming, grinding, etc.) and different types of metals (aluminium,
titanium, copper, brass, etc.) in the machining area. Reduction in
consumption of vegetable based cutting fluid unlike the conven-
tional flooding method leads to minimize the machining cost and
environmental impacts.
Acknowledgement
The authors are grateful to TUBITAK (Project number: 107M164).
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