Abstract
Metalworking fluids (MWFs) can greatly improve the machinability of materials and increase cutting tool life. There are a range of MWF products available on the market, however there are very few reliable low cost machining based fluid screening tests which can help select the most suitable candidate. This study developed a novel and rigorous single point milling (SPM) procedure carried out under controlled conditions, which would provide fluid performance differentiation for a range of typical aerospace alloys. The use of a single insert with a controlled geometry reduced machining variance and ensured performance repeatability. Tool life curves were used to determine optimum machining surface speeds for Inconel 718 (In718) of 80 m/min and Ti-6Al-4V (Ti64) of 160 m/min. Carrying out trials using five different cutting fluid products within a controlled tool life window clearly demonstrated that the SPM machining test was able to differentiate performance on both In718 and Ti64 material. Overall a 65% and 53% performance difference in tool life behaviour was observed between the best and worst performing fluids for In718 and Ti64, respectively.
Highlights
Metalworking can be divided into two general types of processes: metal deformation and metal removal.[1]
This logarithmic relationship between speed and tool life is commonly referred to as a Taylor curve, pioneered by Taylor in 1907.23 Tool life data was used in this work to select a suitable machining surface speed for both materials for the different test fluids
The aim of this study was to develop a lab based machining test, which would allow the assessment of metalworking fluid (MWF) performance and differentiation when milling aerospace alloys
Summary
Metalworking can be divided into two general types of processes: metal deformation (such as forming or rolling) and metal removal (including grinding and cutting).[1] Metal removal is used for part production when there is a need for high dimensional accuracy and when more simplistic operations cannot achieve the required specifications or rate. The temperature and pressure conditions occurring in metal cutting are extreme, especially with modern difficult to machine materials like titanium alloy Ti-6Al-4V (Ti64), which lead to rapid tool wear and to deformation of the machined surface.[2] The technical and economic feasibility of these operations are constrained by tool wear. In the late 19th century, Taylor demonstrated the practical value of using liquids to aid in metal cutting.[3]
Sign-in/Register to view highlights & summary 
Published Version (
Free)
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call