Abstract
Effects of the elimination of water-based cutting fluids on surface finish, chip disposability, tool life and production cost are investigated when a plain medium carbon steel is turned with a coated carbide tool up to a cutting speed of 400 m/min. Wet finish machining can be replaced by dry without any deterioration of machining characteristics: a cutting speed of about 350 m/min, a feed of 0.25 mm/rev and a depth of cut of 0.5 mm are recommended. Although the elimination of a cutting fluid shortens the life of the carbide tool in dry rough machining, the production cost with the optimum cutting speed is little higher than that in wet machining. Finite element machining simulation shows that the temperature in the tool-chip contact area is not substantially affected by a cutting fluid when the heat transfer coefficient varies from 1 to 30 000 Wm-2K-1. It is recommended that the use of a high-thermal-conductivity tool such as cBN produces a better cooling effect than the application of cutting fluid with respect to reducing the tool-chip contact temperature.
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