A Finite Element Analysis Based Approach to Understand the Effects of Targeted Minimum Quantity Cutting Fluid Application on Surface Integrity

Abstract

Minimum quantity cutting fluid application is targeted upon the rake face and the flank face of the tool to improve the tool life and surface integrity. By strategically targeting/applying the cutting fluid on the tool rake and flank surfaces, the temperatures along the rake face and flank face are altered, thereby affecting surface machining-induced residual stresses. The magnitude of temperature alteration and thereby the machining-induced residual stresses can be affected by the amount of targeted cutting fluid and the composition of the targeted cutting fluid. In this paper, the authors use a numerical finite element approach to understand the effects of the strategically targeted cutting fluid on the flank face improves the sub-surface residual stresses by reducing the tool-tip machining temperatures when machining AISI 1045 annealed steel with an uncoated cemented carbide tool. The machining-induced residual stresses generated from the finite element model have shown that the temperatures near the tool tip reduce by targeting cutting fluid on the flank face. The targeted cutting fluid reduced the machined workpiece temperatures and also assisted in cooling the cutting tool from the flank and rake side.