Abstract
The present paper describes the influence of water-miscible cutting fluids on tool life (flank wear) and crater wear of various coated cutting tools and finished surface roughness, as compared with the cases of dry cutting and wet cutting using cutting oil in hobbing in an attempt to improve the working environment. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The following results were obtained. (1) In the case of an uncoated tool, cutting oil was more effective than dry cutting in reducing flank wear. Cutting oil and water-miscible cutting fluids were more effective in reducing flank wear than dry cutting using TiN- and TiAlN-coated tools. The use of water-miscible cutting fluids in conjunction with TiSiN- and AlCrSiN-coated tools prolongs tool life. (2) For all coated tools, the use of cutting oil or water-miscible cutting fluids were effective in reducing crater wear. Especially, water-miscible cutting fluids were effective for TiSiN- and AlCrSiN-coated tools. (3) Regarding the finished surface roughness, in the case of dry cutting, the finished surface roughness was similar for various types of coating films. When using cutting oil or a water-miscible cutting fluid, the finished surface roughness improved compared with dry cutting, independent of the type of coating film applied. The finished surface roughness obtained using water-miscible cutting fluid was approximately the same as or smaller than that obtained using cutting oil. (4) With respect to flank wear, crater wear, and finished surface roughness, the water-miscible cutting fluid of emulsion type containing a large amount of synthetic lubricating additives was suitable for the AlCrSiN-coated tool.
Highlights
The present paper describes the influence of water-miscible cutting fluids on tool life and crater wear of various coated cutting tools and finished surface roughness, as compared with the cases of dry cutting and wet cutting using cutting oil in hobbing in an attempt to improve the working environment
In the case of the TiAlN-coated tool, using Oil A, the tool life is reached at a cutting groovelength of 6.9 m (22 gears), but the tool lives using the three water-miscible cutting fluids are shorter than that using Oil A
The tool lives obtained using the three water-miscible cutting fluids were longer than that using Oil A, and, when using Fluid B, the tool life is reached at a cutting groove length of 16 m (52 gears), which is longest among the water-miscible cutting fluids
Summary
The present paper describes the influence of water-miscible cutting fluids on tool life (flank wear) and crater wear of various coated cutting tools and finished surface roughness, as compared with the cases of dry cutting and wet cutting using cutting oil in hobbing in an attempt to improve the working environment. (4) With respect to flank wear, crater wear, and finished surface roughness, the water-miscible cutting fluid of emulsion type containing a large amount of synthetic lubricating additives was suitable for the AlCrSiN-coated tool. (1) The water-miscible cutting fluid (emulsion type) used in the experiment prolonged the tool life, and the finished surface roughness is equivalent to that obtained by the conventional water-immiscible cutting oil for hobbing, even if the cutting speed is changed (Matsuoka et al, 2002). The cutting performance of water-miscible cutting fluids for various coated tools in terms of tool wear and finished surface roughness was investigated in comparison with that of dry cutting and the use of water-immiscible cutting oil in wet cutting
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