Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Abstract

Predicting the tribological behaviour in the secondary shear zone in the metal-cutting processes is considered a significant challenge in contemporary research. This work investigated the frictional performance in the secondary shear zone of a planing process using a modified ball-on-disc open tribometer. The values of the coefficient of friction (COF) were tracked between an AISI4140 + QT disc (chip) and a cemented carbide ball (cutting tool) coated with TiAlN under three contact pressures of 0.5, 1, and 2 GPa at a range of sliding speeds starting from 0.2 m/s to 1.6 m/s. The tests were conducted under both dry and lubricated conditions using three commercial cutting fluids of CSF 35 straight oil, Vasco 6000, and Zubora 67H emulsions. Also, the MWFs were tested for their rheological properties and wettability. The tribometer results validated the same COF trend as that in the actual metal-cutting experiments, particularly at 0.5 and 1 GPa in dry conditions. Moreover, Zubora 67H emulsion is proven to be the optimal choice due to it reducing the COF between the rubbing contacts by up to 78%. Furthermore, it showed the lowest contact angle and viscosity index, revealing its ability to easily penetrate, especially at higher temperatures, within the secondary cutting zone.