Effect of Cutting Fluids on the Flank Wear of High Speed and Carbide Tipped Cutting Tools
The major needs in machining are high material removal rate, good work surface finish and low tool wear. These objectives can be achieved by reducing tool wear using proper cutting fluid during machining.The effect of some cutting fluids namely: Mentholated spirit, paraffin, and soluble oil on the flank wear of High speed steel and carbide tipped tools by orthogonal cutting has been studied. Cente lathe was used for cylindrical turning operated at a speed of 370rpm and depth of cut of 1mm to machine aluminum, brass, mild steel and medium carbon steel workpiece. It was observed that soluble oil with 20% water concentration gave minimum flank wear among the cutting fluids used. The flank wear were .0.002mm, 0.008mm, 0.009mm and 0.012mm for soluble oils, mentholated spirit, paraffin and dry machining respectively cutting fluid using high speed Steel cutting tool and Aluminum workpiece. For the workpiece, aluminum gave minimum tool flank wear, followed by brass. mild Steel and Medium Carbon Steel respectively. Carbide tipped tool also exhibited better flank wear resistance than High speed steel. Soluble oil gave the minimum flank wear and best surface finish for all workplace and so have the capacity to give a longer tool life when compared with other cutting fluid studied. (c) JASEM http:/dx.doi.org/10.4314/jasem.v18 i2.2 Introduction: The correct selection and use of cutting fluids is one of the most important and often one of the cheapest factors in enhancing the performance of cutting tools (Timings, 1997) In metal cutting process, the condition of the cutting tools plays a significant role in achieving consistent quality and also for controlling the overall cost of manufacturing. To obtain optimum rates of metal removal and at the same time maintain optimum tool service life, it is necessary to both lubricate and cool the chip tool interface. Cutting fluids are designed to fulfill one or more of the following functions (Timings, 1997, Yildiz et al,2007 ,Vikram et al,2007) To cool the tool and work piece. To lubricate the chips tool interface 'and reduce tool wear due to friction and abrasion, To improve the finishing of the machined surface. Ta flush away the chips from the cutting zone. To prevent the corrosion of the work and machine. To prevent chip welding(formation of a built up edge) Cutting fluids reach the chip tool interface by a number of processes such as diffusing through the highly distorted structure of the metal in the chip and by capillary action. Several authors have applied different methods to source lubricants for metal forming and machining (Avitzur, 1963; Babaagba, 1986; Cholakou and Rowe. 1982) Some of these tests include measurement of tool wear rate or tool life, determination of chip compression ratio and coefficient of friction ,measurement of temperature and measurement of surface roughness, Husa (1957) Yahya 2010 carried out an eexperimental iinvestigation on effect of cutting fluids in turning with coated carbides Tool.Flank wear, cutting force and surface roughness value were measured throughout the tool life and the results obtained compared with dry and wet cooled turning. The results indicated substantial reduction in tool wear when wet cooled turning was applied, which enhanced the tool life, Obi (1997) investigated the performance of local vegetable oils (i.e. ground nut oil, palm oil, and cotton seed oil) as cutting fluid in orthogonal cutting of aluminum and brass using high speed steel cutting tool. His result which was based on surface quality and reduction on chip compression ratio showed that groundnut oil performed better in the machining of Effect of Cutting Fluids on the Flank Wear 160 1 JO; OSARENMWINDA aluminum, while cotton seed oil showed a sparingly better performance than the rest in the machining of brass at all speeds tested. Kurimoto and Barrow (1981) did a study on the influence of soluble and straight cutting oils when turning alloy steel with high speed steel tools. The results indicated that under practical cutting conditions, the straight oil did not penetrate the chip tool interface and hence did not exhibit a lubricating action, whilst the soluble oils showed considerable penetration. Muktar and lbhadode (1999) formulated soluble oil from locally available materials. These materials were low grade automotive oil. Emulsifying wax, ordinary washing soap and other additives. Report shows that it compared favourably with the commercial soluble oil The former has a maximum deviation of 4.2% flank wear over the latter when machining operation was carried out with center lathe at a feed of 0.15mm/rev, and depth of cut of 02mm using medium carbon steel work piece and high speed steel cutting tool. The major needs in machining are high material removal rate, good work surface finish and low tool wear. These objectives can be achieved by reducing tool wear using proper cutting fluid during machining. This paper aims to determine the effect of cutting fluids on the flank wear of high speed steel and carbide tipped cutting tools It is hoped that this paper will assist in the selection of cutting fluids, cutting tools and workpiece for optimum cutting condition.