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Influence of cooling and lubrication on chip formation and its form in turning

Leppert T.

Journal of Polish CIMAC

2011

Vol. 6, no 3

97-106

Machining with the use of cooling and lubrication liquids (called wet machining) is still the primary method of shaping constructional materials. However, economic and ecological factors cause that wet machining is being replaced by processes which use minimal quantities of cooling and lubrication liquids (MQL machining) or do not use them at all (dry machining). Eliminating cooling and lubrication from cutting processes results in higher temperatures during the cutting process and worse tribological conditions around the moving surfaces between the tool and workpiece. This, on the other hand, causes changes of the conditions in which the chip is formed and a different form of the chips. Another consequence is problems related to hot chips and difficulty measuring hot workpieces. The form of the chip is an important factor particularly noticeable in automated part manufacturing lines, where the chip has to be easily removable from the cutting zone - especially if the parts are made of difficult-to-machine materials. This paper presents results of an investigation into the conditions of chip formation and its form in dry, MQL turning as well as in turning with emulsion. The machined materials include constructional steel C45 and austenitic stainless steel X2CrNiMo 17-12-2. The obtained results confirm a significant role of cooling and lubrication conditions which, however, depends on the selected cutting parameters and the properties of the workpiece material. The results also helped to select cutting conditions which are most suitable for automated machining.