Biological Stability of Water-Based Cutting Fluids: Progress and Application

The application of cutting fluid in the field of engineering manufacturing has a history of hundreds of years, and it plays a vital role in the processing efficiency and surface quality of parts. Among them, water-based cutting fluid accounts for more than 90% of the consumption of cutting fluid. However, long-term recycling of water-based cutting fluid could easily cause deterioration, and the breeding of bacteria could cause the cutting fluid to fail, increase manufacturing costs, and even endanger the health of workers. Traditional bactericides could improve the biological stability of cutting fluids, but they are toxic to the environment and do not conform to the development trend of low-carbon manufacturing. Low-carbon manufacturing is inevitable and the direction of sustainable manufacturing. The use of nanomaterials, transition metal complexes, and physical sterilization methods on the bacterial cell membrane and genetic material could effectively solve this problem. In this article, the mechanism of action of additives and microbial metabolites was first analyzed. Then, the denaturation mechanism of traditional bactericides on the target protein and the effect of sterilization efficiency were summarized. Further, the mechanism of nanomaterials disrupting cell membrane potential was discussed. The effects of lipophilicity and the atomic number of transition metal complexes on cell membrane penetration were also summarized, and the effects of ultraviolet rays and ozone on the destruction of bacterial genetic material were reviewed. In other words, the bactericidal performance, hazard, degradability, and economics of various sterilization methods were comprehensively evaluated, and the potential development direction of improving the biological stability of cutting fluid was proposed.

Predicting Cutting Force and Primary Shear Behavior in Micro-Textured Tools Assisted Machining of AISI 630: Numerical Modeling and Taguchi Analysis

The cutting tool heats up during the cutting of high-performance super alloys and it negatively affects the life of the cutting tool. Improved tool life can enhance both the machinability and sustainability of the cutting process. To improve the tool life preferably cutting fluids are utilized. However, the majority of cutting fluids are non-biodegradable in nature and pose harmful threats to the environment. It has been established in the metal cutting literature that introducing microgrooves at the cutting tool rake face can significantly reduce the coefficient of friction (COF). Reduction in the COF promotes anti-adhesive behavior that improves the tool life. The current study numerically investigates the orthogonal cutting process of AISI 630 Stainless Steel using different micro grooved cutting tools. Results of the numerical simulations point to the positive influence of micro grooves on tool life. The results of the main effects found that the cutting temperature was decreased by approximately 10% and 7% with rectangular and triangular micro grooved tools, respectively. Over machining performance indicated that rectangular micro groove tools provided comparatively better performance.

Performance of Castor Oil and Neem Oil as Metal Cutting Fluids in Drilling Inconel 718 Using MQL Technique on Tool Wear and Surface Roughness

Inconel 718 is hard to cut material due to its high hardness, high strength at elevated temperatures, low thermal diffusivity and affinity to react with tool materials. The high temperature during machining results in aggressive tool wear and poor hole quality. Therefore, the application of metal cutting fluids (MCF) as a lubricating and cooling agent is very significant in the drilling of nickel-based superalloys such as Inconel 718. The present study embraces these issues by evaluating the performance of non-edible vegetable oils such as castor and neem oil under minimal quantity lubrication (MQL) conditions towards the tool wear and surface roughness. The drilling experiments were carried out using coated (TiAlN) carbide drill with diameter of 6 mm at different cutting speeds of 10 and 20 m/min and a constant feed of 0.015 mm/rev. The results of this study showed that castor oil significantly outperformed the neem oil in drilling performance regarding tool wear and surface roughness.

Metal chips preparation for utilization using advanced reagents

The article touches upon the problems of utilization of metal chips containing residues of cutting fluids. The research results are shown for nickel alloy chips washing to remove cutting fluids with the use of various reagents available on the current market. In the course of the research, an original colorimetric express method for assessing the contamination of metal chips was developed, which allows quickly and efficiently establishing the quantitative drop in the cutting fluids content in the chips after the washing. Conclusions are made as to the most effective reagent from the point of view of economics and quality of cutting fluid removal.

Investigation of the Cutting Uid'S Ow and its Thermomechanical Effect on the Cutting Zone Based on Uid-Structure Interaction (FSI) Simulation

Cutting fluids are an important part of today's metal cutting processes, especially when machining aerospace alloys. They offer the possibility to extend tool life and improve cutting performance. However, the equipment and handling of cutting fluids also raises manufacturing costs. To reduce the negative impact of the high cost of cutting fluids, cooling systems and strategies are constantly being optimized. In most existing works, the influences of different cooling strategies on the relevant process parameters, such as tool wear, cutting forces, chip breakage, etc., are empirically investigated. Due to the limitations of experimental methods, analysis and modeling of the working mechanism has so far only been carried out at a relatively abstract level. For a better understanding of the mechanism of cutting fluids, a thermal coupled two-dimensional simulation approach for the orthogonal cutting process was developed in this work. This approach is based on the Coupled Eulerian Lagrangian (CEL) method and provides a detailed investigation of the cutting fluid’s impact on chip formation and tool temperature. For model validation, cutting tests were conducted on a broaching machine. The simulation resolved the fluid behavior in the cutting area and showed the distribution of convective cooling on the tool surface. This work demonstrates the potential of CEL based cutting fluid simulation, but also pointed out the shortcomings of this method.