Abstract
In order to improve the cutting performance in broaching, the lubrication and cleaning effects offered by water-based cutting fluids with green additives need to be studied from the viewpoint of green manufacturing. Therefore, water-based solutions with castor oil, surfactant (linear alkylbenzene sulfonate, LAS), and nanographite were prepared by ultrasonic agitation and sprayed into the zone of broaching via atomization. The performances of the cutting fluids, in terms of the viscosity, specific heat, wetting angle, and droplet size, were evaluated to discuss their effects on the broaching load. Among the fluids, the addition of LAS into oil-in-water (WO-S), where its cutting fluid with 10 wt.% castor oil and 1.5 wt.% surfactant, exhibited the lowest broaching force. With regard to the lubricating and cleaning mechanisms, WO-S has good wettability and permeability, and hence, can lubricate the cutting edge of the tool to decrease the cutting load, cool the cutting edge to keep it sturdy, and clean the surface of the cutting edge to keep it sharp. The results reveal that the simultaneous addition of castor oil and LAS had remarkable effects on the lubrication and cleaning, and resulted in a broaching load reduction of more than 10% compared to commercial cutting fluids. However, the addition of nanographite could not improve the lubrication owing to its agglomeration.
Highlights
Broaching is an efficient and fine cutting process, and is widely used in the aerospace, automobile, vessel, and energy industries
3.1 Broaching load with cutting fluids The broaching load is an important factor in evaluating http://friction.tsinghuajournals.com∣www.Springer.com/journal/40544 | Friction
The mean high and mean low broaching loads decreased with increasing concentration of castor oil in the W-O cutting fluids
Summary
Broaching is an efficient and fine cutting process, and is widely used in the aerospace, automobile, vessel, and energy industries. Owing to the heavy cutting load (at least 10 kN) in broaching process, research to identify suitable coolant lubricants is imperative to reduce the broaching temperature and friction, and thereby improve the tool life and machining quality. Cambiella et al [14] evaluated the effect of the concentration of three different emulsifiers (anionic, non-ionic, and cationic surfactants) on the extreme pressure properties of oil-in-water emulsions in machining operations. Coconut oil with a nanoparticle suspension performed better than SAE-40 oil in terms of the cutting temperature, flank wear, and surface finish. Klocke et al [24] showed MQL technology improved the surface finish and tool life, and reduced the machining forces. This study focuses on the lubrication performance of water-based cutting fluids with green additives, such as castor oil, surfactant (linear alkylbenzene sulfonate, LAS) and nanographite, in broaching. The lubricating and cleaning mechanisms are analyzed using the obtained results
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