Effect of High-Pressure Coolant on Temperature, Chip, Force, Tool Wear, Tool Life and Surface Roughness in Turning AISI 1060 Steel

Abstract

Metal cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions. The use of cutting fluid generally causes economy of tools and it becomes easier to keep tight tolerances and to maintain workpiece surface properties without damages. However, the conventional types and methods of application of cutting fluid have been found to become less effective with the increase in cutting speed and feed when the cutting fluid cannot properly enter the chip-tool interface to cool and lubricate due to bulk plastic contact of the chip with the tool rake surface. Besides that, often in high production machining the cutting fluid may cause premature failure of the cutting tool by fracturing due to close curling of the chips and thermal shocks. Because of them some alternatives has been sought to minimize these problems. Some of these alternatives are cryogenic machining, minimum quantity lubricant machining and machining with high-pressure coolant jet. This paper deals with experimental investigation on the role of high-pressure coolant on cutting temperature, chips, cutting forces, tool wear, tool life and surface finish in turning of AISI 1060 steel at industrial speed-feed combinations by uncoated carbide inserts. The encouraging results include significant reduction in cutting forces, tool wear, surface roughness and significant improvement in tool life by high-pressure coolant jet mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction.

Keywords

• High-pressure coolant
• Temperature
• Chip reduction coefficient
• Force
• Tool wear
• Tool life and Surface roughness

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