Machining Processes - I

MT 164

CUTTING FLUIDS
 Cutting Fluids

Definition:
A cutting fluid is any liquid or gas that is applied
directly to machining operation to improve cutting
performance.
 Functions Of Cutting Fluids

Primary Functions:
1. Cooling
2. Lubrication

Secondary Functions:
1. Corrosion protection of the machined surface
2. Enabling part handling by cooling the hot
surface
3. Flushing away chips
Advantages of Using Cutting Fluids
 Higher surface finish quality and better
dimensional accuracy are obtained from cutting
fluids
 Reduction of tool costs
 Reduce tool wear, tools last longer
 Increased speed of production
 Reduce heat and friction so higher cutting speeds
 Reduction of labor costs
 Tools last longer and require less regrinding, less
downtime, reducing cost per part
 Reduction of power costs
 Friction reduced so less power required by
machining
 Disadvantages of Cutting Fluids

 For certain Machine tools- A costly engineering

system is required for applying the fluid
 The fluid used has to be prepared and after use,
filtered for re-use of disposed
 Some fluids have a health risk if not used correctly
causing problems.
 Some cutting materials are affected by thermal
shock e.g. cemented carbides. Use of cutting
fluids should be avoided for these materials
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- Characteristics of a Good Cutting Fluid
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1. Good cooling capacity
2. Good lubricating qualities
3. Resistance to rancidity (unpleasant
taste, smell )
4. Relatively low viscosity
5. Stability (long life)
6. Rust resistance
7. Nontoxic (non-poisonous)
8. Transparent
9. Nonflammable
 Types Of Cutting Fluids
Cutting fluids can be broken into four main
categories:
1. cutting oils,
2. water miscible fluids
3. gasses
4. paste or solid lubricants.
 Water is the best fluid for cooling. It has the best ability to carry
heat away. Water, however, is a very poor lubricant and causes
rust.

 Oil is great for lubrication but very poor for cooling. Oil is also
flammable.
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- Liquid Cutting Fluids
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 Most commonly used cutting fluids
 Either aqueous based solutions or cutting oils
 Fall into these categories
1. Cutting oils
2. Water miscible fluids
a) Emulsifiable oils
b) Chemical cutting fluids
 Types of Cutting Fluids

Cutting Oils
 cutting oils are not mixed with water.
 Cutting oils are generally mixtures of mineral oil and
animal, vegetable, or marine oils to improve the
wetting and lubricating properties.
 Sulfur, chlorine, and phosphorous compounds are
sometimes added to improve the lubrication qualities
of the fluid for extreme pressure applications which
helps in forming a strong layer on surface.
 Types of Cutting Fluids
Emulsions (Oil mixed in Water)
 Emulsion is a term that describes soluble oils in water. An
emulsion is a suspension of oil droplets in water. Soluble
oils are mineral oils that contain emulsifiers. Emulsifiers
(prepared from glycerol etc) are soap-like materials that
allow the oil to mix with water. Emulsions (soluble oils) when
mixed with water produce a milky white coolant.
 They combines the coolant and lubricating properties.
 A typical ratio of water to oil is 30:01.
 Lean concentrations (more water-less oil) provide better
cooling but less lubrication.
 Rich concentrations (less water- more oil) have better
lubrication qualities but poorer cooling.
 Types of Cutting Fluids

Chemical Fluids
 Chemical coolants are also miscible cutting fluids. Chemical
cutting fluids are the chemicals which are mixed with water
easily with the help of wetting agent (surfactants like Alkane
Sulphonate).
 They provide good cooling quality but less lubrication as
compared to other fluids.
 The chemical components in the fluid are used to enhance
the lubrication, bacterial control, rust, and corrosion
characteristics. The dissolved chemicals includes sulfur and
chlorine etc.
 There are several types of chemical coolants available,
including coolants for extreme cutting conditions.
 Types of Cutting Fluids
Gasses
 Cutting oils and water miscible types of cutting fluids are
the most widely used. Gasses are also sometimes used
like Compressed air and inert gasses. Carbon dioxide,
Freon, and nitrogen are used sometimes as coolant.
Paste and Solid Lubricants
 Waxes, pastes, soaps, graphite, and molybdenum
disulfide may be used. These are generally applied
directly to the work piece or tool, or in some cases,
impregnated directly into a tool, such as a grinding
wheel.
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- Application Methods of Cutting Fluids
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3  Cutting-tool life and machining operations influenced
by way cutting fluid applied
 There are three common methods of application:
1. Flood application
2. Jet application
3. Mist application
 1. Flood Application of Fluid
 A flood of cutting fluid is applied on the work piece.
 Here, a large volume of fluid is pumped to the metal
removal interface.
 The fluid is collected and then reused many times.
 2. Jet Application of Fluid
 A jet of cutting fluid is applied on the work
piece.
 Fluid is applied on cutting interface through a
nozzle with produces high pressure.
 Mist Application of Fluid

 Cutting fluid is atomized by a jet of air .

 Another method, Micro-lubrication, provides fluid to the
cutting interface in the form of a mist, providing the
lubrication effect.
 Because of the small volume used, the fluid is not collected
for reuse
 Cutting Fluid Contamination and solution

Contaminants:
 Tramp oil (machine oil, hydraulic fluid, etc.)
 Garbage (cigarette butts, food, etc.)
 Small chips
 fungi, and bacteria
Solution:
 Replace cutting fluid at regular and frequent intervals
 Use filtration system continuously or periodically
 Cleaning the fluid
 Dry machining
 Types of Cutting Fluids

Definitions:
Surfactant A substance that tends to reduce the surface
tension of a liquid in which it is dissolved.
Surface Tension The tension of the surface film of a
liquid caused by the attraction of the particles in the
surface layer by the bulk of the liquid, which tends to
minimize surface area
Atomize Reduce (something) to atoms or other small
distinct units.
Mist A cloud of tiny water droplets suspended in the
atmosphere