Abstract
The application of conventional cutting fluids in machining operations is harmful and not eco-friendly. In this context, the present work focuses on environmental friendly cutting fluids such as vegetable oil based cutting fluids (VBCFs). The objective of this work is to determine the influence of vegetable oil based cutting fluids (sesame and coconut oil) with extreme pressure (EP) additive on machining performance. Cutting forces, cutting tool temperature, tool flank wear and surface roughness are measured during turning of AISI 1040 steel with coated carbide tool. Machining performance of VBCFs with EP additive is compared with conventional cutting fluid and VBCFs without EP additive. The results indicated that sesame and coconut oils with EP additive improved machining performance compared to other lubrication conditions. Coconut oil with EP additive decreased the feed force by 31%, thrust force 28%, cutting force 20%, cutting tool temperature 7% and tool flank wear 34% and surface quality increased by 33% compared to sesame oil with EP additive.
Highlights
Friction is a natural phenomenon that is always encountered in machining
The forces are reduced with addition of extreme pressure (EP) additive in vegetable oil compared to conventional cutting fluid and base oils
The combined effect of EP additive and vegetable oil caused to reduction in tool flank wear, which is more effective with 5% EP additive in coconut oil
Summary
Friction is a natural phenomenon that is always encountered in machining. During machining, friction between tool and workpiece lead to rise in high temperatures, which results less dimensional accuracy and poor surface quality of the workpiece. In this study the effect of soybean-based cutting fluid was compared with petroleum-based cutting fluid when high carbon alloy steel was machined in terms of improving surface finish and reducing tool wear. The performance of VBCFs with 8% and 12% sulfur based EP additive were evaluated in terms of cutting and feed forces, tool wear and surface roughness. Results indicated that 8% of EP additive contributed canola oil based cutting fluid gave better performance than that of semi-synthetic and mineral oil based cutting fluids in terms of reduced surface roughness, feed force and tool wear. Kuram et al [21] investigated the effect of EP additive included VBCFs in terms of reduced cutting force, increased tool life and improved surface finish during end milling of AISI 304 stainless steel. Machining performance is measured in terms of feed force (Fx), thrust force (Fy) and cutting force (Fz), cutting tool temperature, tool flank wear and surface roughness (Ra) during turning of AISI 1040 steel with coated carbide tool
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