Dosage Based Directional Minimum Quantity Fluid Application in Machining

Abstract

There is an ever-increasing focus on surface integrity and machined surface quality of the machined surface and sub-surface to improve product quality, thereby improving its service life and sustainability. Machined sub-surface quality is influenced by the cutting tool system, cutting conditions and the cutting fluid system. However, past work on the influence of cutting fluid application, especially targeted application of minimal quantity fluid (MQF; varying minimum quantity of coolant and lubricant) which has never been addressed on surface integrity, is limited or non-existent. Thus, an experimental study involving face turning of AISI 1045 steel with flat-faced uncoated carbide tool was conducted with different cutting fluid combinations and at varied locations in the tool–workpiece space. This study is aimed to address machining performance effects (tool–chip contact area, cutting forces, etc.) and machining induced surface integrity (surface roughness and residual stresses). Results showed that the coolant application on the tool flank face improved the surface integrity. In addition, results emphasized the importance of targeted MQF on surface integrity and cutting tool performance, thus providing a cleaner and more efficient machining process.