Abstract
Surface milling of hardened steel is carried out with copious supply of cutting fluid and is obviously associated with problems related to procurement and storage of cutting fluid. The disposal of cutting fluid has to comply with environmental legislation such as OSHA regulations. The present investigation proposes an environment friendly minimal pulsed jet cutting fluid application scheme for surface milling of AISI4340 steel with a hardness of 45 HRC using commercially available carbide tools. This scheme can be implemented as such on the shop floor with out the need for any major alternations on the existing facilities and it was observed that the new scheme is not only environment friendly but also provided better cutting performance when compared to conventional wet milling which requires copious supply of cutting fluid.
Highlights
Conventional surface milling of hardened steel needs application of large quantities of cutting fluid
Surface milling of hardened steel is carried out with copious supply of cutting fluid and is obviously associated with problems related to procurement and storage of cutting fluid
The present investigation proposes an environment friendly minimal pulsed jet cutting fluid application scheme for surface milling of AISI4340 steel with a hardness of 45 HRC using commercially available carbide tools. This scheme can be implemented as such on the shop floor with out the need for any major alternations on the existing facilities and it was observed that the new scheme is environment friendly and provided better cutting performance when compared to conventional wet milling which requires copious supply of cutting fluid
Summary
Conventional surface milling of hardened steel needs application of large quantities of cutting fluid. Apart from the fact that it gives a foul smell, disposal of cutting fluid is a problem and one has to comply with environmental legislation In this context, dry milling is a logical alternative which is totally free from the problems associated with storage and disposal of cutting fluid. Ultra hard cutting tools may be introduced but the existing machine tools may not be rigid enough to support dry hard milling In this context the best alternative is to introduce pseudo dry milling or milling with minimal fluid application. In this method, extremely small quantity of cutting fluid is introduced at high velocity (70 m/s) in the form of tiny droplets at critical zones so that for all practical purposes it resembles dry machining. The most important aspect of this scheme is that it can be implemented on the shop floor and offers better cutting performance when compared to conventional wet milling while using very small quantities of cutting fluid (about 5-15 ml/min)
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