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minimum quantity lubrication (MQL), compressed air and emulsion on toolchip contact
length. The results are compared with dry cutting in terms of toolchip contact and chip
5 September 2007
morphology. The toolchip contact area was examined with scanning electron microscopy
(SEM), optical microscopy and white light interferometer. The orthogonal turning test series
were planned in such a way that the engagement time was altered from long to very short
(intermittent turning). The results showed that MQL and compressed air lowers the con-
Keywords:
tact length compared to dry cutting at short and longer engagement times. The contact
MQL
length is almost the same for MQL and compressed air assisted cutting, but the difference
Air
is in sliding region with the shorter engagement times. Emulsion assisted cutting gave the
Dry
shortest contact length. The chips were also examined with optical and scanning electron
Contact length
microscopy. Wider chips were observed with dry cutting which is a result of side ow. Dif-
Seizure
ferent oil amount was also investigated with TiN coated inserts. The effect of oil and air
Sliding
component of MQL on the contact length is understood that helps to clarify their role in
the whole process. It is concluded that MQL is a very suitable method for short engagement
time machining.
2007 Elsevier B.V. All rights reserved.
1.
Introduction
The high percentage of cutting uids cost in the overall manufacturing cost have favored the use of dry and near-dry cutting
(Klocke et al., 2006; Braga et al., 2002; Dahr et al., 2006; Weinert
et al., 2004; Schact et al., 2005; Tasdelen and Johanson, 2006).
Moreover, it is not only the cost that justies dry machining
but also the environmental aspects (Klocke et al., 2006; Braga
et al., 2002; Dahr et al., 2006; Weinert et al., 2004). Minimum
quantity lubrication (MQL) is a method that enables reducing the amount of cutting uids. MQL consists of a mixture of
pressurized air and oil microdroplets applied directly into the
Corresponding author. Tel.: +46 73 657 3924; fax: +46 31 772 1313.
E-mail address: bulent@chalmers.se (B. Tasdelen).
0924-0136/$ see front matter 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.10.027
interface between the tool and the chip. However, the question of how the lubricants can decrease the friction under very
high temperatures and loads is still not answered especially
for long engagement times.
Over 120 years ago, Mallock wrote Lubricants seem to act
by lessening the friction between the face of the tool and the
shaving, and the difculty is to see how the lubricant gets
there. The simplest machining process, turning with creation
of a continuous chip, is the most severe as far as friction is concerned. Compared to milling, with its short cutting distance
per cutting edge engagement, in turning the large contact
stresses common to all machining processes are combined
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In order to see the effect of oil droplets and air on the contact length, the whole engagement time was divided into small
engagement intervals. This enables to clarify the lubrication
and cooling effects of MQL on the contact length.
2.
Experimental set-up
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200
0.1
2.5
Cutting
time (sec)
Engagement time
in the section (s)
0.0678
0.0226
0.0113
0.0056
Total engagement
time (s)
5.4287
5.4287
5.4287
5.4287
5.4287
3.
rial (100Cr6) was turned into 2.5 mm thickness cylinder and
machined with 1.5 mm circular saw on the longitudinal axis
to have different number of grooves for different tests. By
increasing and decreasing the number of grooves, the engagement time of the section (between two grooves) was altered.
The engagement time in the section was 0.06786 s for two-
The tests series started with the comparison of MQL and dry
for different engagement times (two- and six-grooved work
pieces) for uncoated inserts. Then MQL and compressed air
assisted cutting were compared in terms of contact length
and how different contact zones look like. Afterwards, the
Fig. 4 (A) Tool holder and nozzle xture, (B) uncoated inserts, (C) schematic cutting 2D and (D) MQL nozzle direction and
schematic cutting (3D).
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Fig. 5 The work pieces with (A) two grooves and (B) six grooves.
comparison between MQL and compressed air was continued with even shorter engagement time both with coated
and uncoated inserts. The chip morphology and the effect
of oil amount on contact length were also evaluated in the
work.
3.1.
Contact length and chip analysis with uncoated
inserts
MQL decreased the contact length compared to dry cutting for
both short and long engagement time of the section at intermittent turning. When the chip starts to slide on the sliding
region, the material starts hardening due to high deformation
ratio in the shear zone. Due to the high temperature and friction it clads on the insert especially in this sliding region of
the natural contact. The difference in contact length is mainly
seen in the sliding region. The clad material in the sliding
region is thicker for dry cutting especially when cutting the
work piece with six grooves, see Figs. 6 and 7.The surface
topography evaluation of the inserts by vertical scanning interferometry (VSI) shows the natural contact length (Lc) and the
sliding length (Ls) for MQL and dry, as shown in Figs. 6 and 7.
Comparison tests were performed between MQL and compressed air for short and long engagement times. It was seen
that MQL and compressed air give the same total contact
length when cutting two and six-grooved work pieces. The
earlier studies have shown that MQL and only compressed air
have the same cooling effect (Tasdelen and Johanson, 2006).
The same cooling effect results in same chip up-curling radius
for MQL and compressed air that may have resulted in the
same contact length. However, the difference occurs in sliding
region. This difference is observed as clad material in sliding
region as shown in Fig. 8. The difference is obvious when cutting six-grooved work piece, as shown in Fig. 9. Otherwise both
contact length and the thickness of the clad material are the
same for longer engagement time tests (work piece with two
grooves).
To summarize, MQL lowers the contact length compared
to dry cutting and the effect is mainly due to cooling effect
Fig. 6 Contact length comparison between MQL and dry cutting. (A) Optical microscopy image of insert that cut work piece
with two grooves. (B) Optical microscopy image of insert that cut work piece with six grooves. (C) SEM image of insert that
cut with MQL (work piece with two grooves). (D) SEM image of the insert that cut dry (work piece with two grooves). (E) SEM
image of the insert that cut with MQL (work piece with six grooves). (F) SEM image of the insert that cut dry (work piece with
six grooves).
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Fig. 7 Tool-contact surface topography for the inserts from the tests with six-grooved work piece. (A) MQL and (B) dry.
Fig. 8 Contact length comparison between MQL and compressed air assisted cutting. (A) Optical microscopy image of
insert that cut work piece with two grooves. (B) Optical microscopy image of insert that cut work piece with six grooves. (C)
SEM image of insert that cut with compressed air (work piece with two grooves). (D) SEM image of the insert that cut with
MQL (work piece with two grooves). (E) SEM image of the insert that cut with MQL (work piece with six grooves). (F) SEM
image of the insert that cut with compressed air (work piece with six grooves).
Fig. 9 Tool-contact surface topography of the inserts from the tests with six-grooved work piece. (A) MQL and (B)
compressed air.
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with 12 grooves. As seen in Fig. 13, not only the clad material in sliding region but also the total contact length is lower
for MQL compared to compressed air. A summary of contact length measurements shows that when the engagement
Fig. 11 Comparison between MQL and compressed air for different speeds (six grooves).
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Fig. 13 Comparison of MQL and compressed air (12 grooves). (A) Optical microscopy view. (B) SEM image of the same insert.
Fig. 15 The contact length values for emulsion and MQL (six grooves).
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Fig. 16 Chip morphology difference (after cutting a work piece with six grooves).
are more up-curled for emulsion. The small radius of curvature is also an indicator of the short contact length. The
chips from MQL and compressed air assisted tests have almost
the same radius of curvature. The largest contact length that
was observed on the rake face was also observed as the
largest radius of curvature of the chips after dry cutting. The
other interesting observation is that chips produced in dry
cutting have side curl radius due to difference in speed on
the inner and outer diameter of work piece, as shown in
Fig. 16. The same phenomenon was not seen for other tests
meaning that the speed is almost the same throughout the
cutting edge during cutting. The chips produced in dry cutting are wider than the chips produced in cutting with MQL,
compressed air and emulsion. The wider chips for dry cutting is a result of side ow in the shear plane that was also
observed in the earlier works of the authors with conventional
inserts.
Side ow is the ow of material to the sides in the shear
plane. The higher the temperature in the shear plane the less
viscous is the material and the more side ow is seen. The
material that ows to the side makes the chips wider than
depth of cut and generally sticks on the hills of feed marks
and makes the surface nish worse.
The difference between MQL and compressed air that
resulted in different contact length was also observed in the
chip shape. The oil droplets affect the contact in the beginning
of chip formation that results in smaller radius of curvature in
the head of the chips, as shown in Fig. 17.
3.2.
Contact length and chip analysis with TiN coated
inserts
The tests were performed with the same set-up that was used
for uncoated inserts. Since the edges were treated and thus
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Fig. 18 Comparison of insert rake face that cut 24-grooved work piece showing a thicker clad material with cracks in air
assisted cutting. (A) SEM image of the insert that cut with MQL. (B) SEM image of the insert that cut with compressed air
assistance. (C) Cracks on the clad material in sliding region of the insert.
Fig. 19 Toolchip contact surface topography of the coated inserts (24-grooved work piece). (A) MQL and (B) compressed air.
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Fig. 21 Comparison of MQL with low and higher amount of oil (work piece with 24 grooves).
Fig. 22 Toolchip contact topography of the coated inserts (24-grooved work piece). (A) MQL with 24 ml/h and (B) MQL with
70 ml/h.
4.
Conclusions
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references
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Childs, T.H.C., 2002. Friction modeling in metal cutting. Wear,
WEA-97762.
Childs, T.H.C., Maekawa, K., Obikawa, T., Yamane, Y., 2000. Metal
Machining, Theory and Applications. ISBN 0 340 69159, pp.
7374.
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