Understanding drop spreading behaviour on WC-10wt%Co cutting tools – an experimental and numerical study

Abstract

WC-Co cutting tools performance under demanding cutting conditions largely depend on the efficiency of the cutting fluid, mainly its ability to remove heat and reduce friction, both highly dependent on the wettability and drop spreading behaviour of the fluid. In this context, this study focuses on the spreading behaviour of machining cutting fluid and water in WC-10 wt%Co cutting tools surface. Contact angles were experimentally measured and then used for performing numerical simulations by the level set method. A contact angle of 75.3˚ and 92.8˚ were measured for the machining cutting fluid and distilled water, respectively, and coincident values were found by numerical simulation, as well as a strong agreement in the drop shape. It was also possible to observe that machining cutting fluid has a lower spreading time than water, due to a lower contact angle and higher viscous dissipation, allowing to reach equilibrium phase sooner. Also, the machining cutting fluid presents a higher drop radius than water, meaning a 24.2% contact area increase over 50 ms of spreading time. Furthermore, numerical simulation showed that the drops spreading over the capillary-inertial time, at the early stage of spreading, follow an exponential dependency with a spreading factor of approximately t1/2, which indicates that the initial spreading of both drops is driven and controlled by the balance between inertial and capillary forces. This work intends to contribute to the knowledge on the phenomena that drive the drop spreading behaviour on WC-10 wt%Co cutting tools, being the development of numerical models to predict this behaviour of utmost importance, since it can lead to the development of novel surface improved tools, with an enhanced lubrification effect and heat removal capacity closer to the cutting zone during machining processes, and consequently allowing an improvement in the tribological and cutting performance of these tools.