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CUTTING FLUIDS
By
M. Satyadev,
Assistant Professor,
Mechanical Engineering Department,
RGUKT
Why to study this Module?
1. Why temperature is generated during cutting process?
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2. What are the sources of heat generation?
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Purpose of determination of cutting temperature:
1. Assessment of Machinability for a given work-tool combination
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2. Design, selection and use of cutting tools
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Sources of Heat:
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2. Secondary deformation
zone
3. Flank wear zone
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Metal cutting & machine tools
Cutting temperatures & cutting fluids
At high speeds chip will take most of the heat compared to tool and work part due to less
convection/conduction.
85-90% of heat goes into chip, rest of the amount is shared by the tool and the job. 5
Effect of cutting temperature on Job and tool:
1. Dimensional inaccuracy of the product due to thermal distortion as well as expansion and
contraction of material
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2. Damage to the machined surface due to corrosion, oxidation, burning, etc.
6. Thermal flaking and fracturing at the cutting edge due to thermal shocks
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Hot Machining:
• This technique is useful in machining High Strength Temperature Resistant (HSTR)
alloys.
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• In this technique heat is applied to the work material in order to reduce the shear strength
in the vicinity of shear zone.
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Analytical Techniques:
Shear Plane Temperatures:
This is based on Energy Balance Techniques
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Aq P ZV c FV F
s J O
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Quantity
Temperature θ K
There are four fundamental variables and so we have four repeating variables in the Pi-Theorem 9
they are chip thickness, cutting velocity, volume specific heat and specific cutting energy.
C i
Q v
1
E c
C V a
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c 1
Q 2
v
Q2
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Experimental Techniques:
1. Use of De-colourising Agent
2. Calorimetric Method
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3. Using Thermocouple principle
I. Tool-work Thermocouple technique
4. Use of Photocell
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Calorimetric Method:
This method is quite simple and inexpensive but not accurate enough. It gives only the average
temperature.
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Metal cutting & machine tools
Cutting temperatures & cutting fluids
v c
chip chip chip chip
w v w c
w w w a
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Seebeck Effect:
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Metal cutting & machine tools
Cutting temperatures & cutting fluids
Thermocouple design is based on the seebeck effect. It states that when the junctions of a thermocouple
are at different temperatures, the differences in the electron emission rates setups a thermos electric
potential which will cause the current flow in the circuit. 13
Cutting temperatures & cutting fluids
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Metal cutting & machine tools
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Tool-Work Thermocouple Technique:
Cutting temperatures & cutting fluids
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Metal cutting & machine tools
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Moving Thermocouple Technique:
This technique is used to know the gradual rise in temperature of continuous chips at low and
moderate cutting velocity
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Metal cutting & machine tools
Cutting temperatures & cutting fluids
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Cutting temperatures & cutting fluids
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Metal cutting & machine tools
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Embedded Thermocouple Technique:
Cutting temperatures & cutting fluids
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Metal cutting & machine tools
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Compound Rake Tool Method:
Cutting temperatures & cutting fluids
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Metal cutting & machine tools
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Photo cell technique:
Metal Cutting & Machine Tools
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Mechanism of Machining
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O
O
1 tan
C P a1
Chip Tool Contact Length:
Variation of different machining parameters on
cutting temperature:
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V S o sin t
0.24
0.4 0.105
C
S
c
t r t S o
0.054
0.11
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Cutting temperatures & cutting fluids
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Metal cutting & machine tools
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1. Large positive rake helps in reducing the cutting forces and hence in reducing the amount of
heat generation
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2. Negative inclination angle also reduce the tool temperature
4. Reduction in principle cutting edge angle helps to reduce cutting temperature by reducing
energy input per unit cutting edge length
5. The magnitude of cutting forces increases proportionally with increase in feed and depth of
cut. So it will raise the cutting temperature.
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General Methods to Reduce the cutting temperature:
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2. Optimum selection of cutting velocity and feed without sacrificing MRR
c V c s o
0.5
sin
power P zV c t s o s f V c
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Fundamentals of Friction Process:
The Classical laws of friction for dry, smooth surfaces in sliding contact were noted by Amonton
1. The coefficient of friction is independent of geometrical area of contact.
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2. The coefficient of friction is independent of applied loads.
These laws are further modified by Holm, Bowden..etc lead to laws of friction
1. The frictional resistance is proportional to the actual area of contact
3. The frictional resistance depends up on the velocity but is nearly constant for wide range
of velocity
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4. The coefficient of friction depends on the material in contact
Frictional resistance in metal cutting:
This may be due to the following three reasons
1. Mechanical interlocking of asperities
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2. A ploughing of the surface asperities by the harder of two metal through softer.
3. Welding of the surface asperities of one metal of the other resulting in metallic
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The obeyance of Amontons law is applicable
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only in the zone I.
The growth of real area of contact depends
upon:
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Cutting temperatures & cutting fluids
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Metal cutting & machine tools
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Stagnant Zone in Cutting Operation:
Theory of Cutting Fluid action at chip tool interface:
Cutting fluids are used for the following purpose:
1. Cooling purpose
2. Friction reduction
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3. To protect the finished surface from corrosion
4. To wash away the chips
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Metal cutting & machine tools
Cutting temperatures & cutting fluids
As the chip moves up the tool face, it contact mainly at the tops of the asperities in the point
contact zone creating capillarity's between the chip and the tool. Under the condition of high
pressure and temperature at the nascent chip surface is highly reactive chemical action
produces weak solid to keep chip and tool apart by reducing friction.
Ex: During machining of steel, cutting fluid with chlorine additive is used. It forms iron
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chloride which has low shear strength value.
The properties which are essential for penetration into the capillarities between the chip and
tool are
1. Wetting and spreading
2. Surface tension
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3. Small fat molecules.
cos sv sl
lv
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Essential Properties of cutting fluids:
1. For cooling:
I. High specific heat, thermal conductivity, and film coefficient
II. Spreading and wettability
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2. For Lubrication:
A. High lubricity without gumming and foaming
B. Wetting and spreading
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Method of application of Cutting fluid:
1. Mist Cooling:
Mist is rapidly formed mixture of highly compressed air and finely divided particles of coolant
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2. Z-Z method of application:
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Water: It is a good coolant but lack of corrosion resistant properties makes it usage limited but
where ever coolant properties are required then it may be used.
Cutting Oils: These are usually mineral oils taken from vegetables, animal or marine which have
good wetting and lubricating properties.
Semi Solid: Wax, Soaps, Pastes, Moly-disulphide, which are used to reduce the friction when they
are applied over rake surface of tool
Cryogenic Fluids: Liquid Co2 are used for effective cooling in some machining operation.
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