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Article history: This paper describes experimental investigations on influence of different media such as
Received 19 January 2007 minimum quantity lubrication (MQL), compressed air and emulsion on tool–chip contact
Received in revised form length. The results are compared with dry cutting in terms of tool–chip contact and chip
5 September 2007 morphology. The tool–chip contact area was examined with scanning electron microscopy
Accepted 10 October 2007 (SEM), optical microscopy and white light interferometer. The orthogonal turning test series
were planned in such a way that the engagement time was altered from long to very short
(intermittent turning). The results showed that MQL and compressed air lowers the con-
Keywords: tact length compared to dry cutting at short and longer engagement times. The contact
MQL length is almost the same for MQL and compressed air assisted cutting, but the difference
Air is in sliding region with the shorter engagement times. Emulsion assisted cutting gave the
Dry shortest contact length. The chips were also examined with optical and scanning electron
Contact length microscopy. Wider chips were observed with dry cutting which is a result of side flow. Dif-
Seizure ferent oil amount was also investigated with TiN coated inserts. The effect of oil and air
Sliding component of MQL on the contact length is understood that helps to clarify their role in
the whole process. It is concluded that MQL is a very suitable method for short engagement
time machining.
© 2007 Elsevier B.V. All rights reserved.
1. Introduction interface between the tool and the chip. However, the ques-
tion of how the lubricants can decrease the friction under very
The high percentage of cutting fluids cost in the overall manu- high temperatures and loads is still not answered especially
facturing cost have favored the use of dry and near-dry cutting for long engagement times.
(Klocke et al., 2006; Braga et al., 2002; Dahr et al., 2006; Weinert Over 120 years ago, Mallock wrote “Lubricants seem to act
et al., 2004; Schact et al., 2005; Tasdelen and Johanson, 2006). by lessening the friction between the face of the tool and the
Moreover, it is not only the cost that justifies dry machining shaving, and the difficulty is to see how the lubricant gets
but also the environmental aspects (Klocke et al., 2006; Braga there”. The simplest machining process, turning with creation
et al., 2002; Dahr et al., 2006; Weinert et al., 2004). Minimum of a continuous chip, is the most severe as far as friction is con-
quantity lubrication (MQL) is a method that enables reduc- cerned. Compared to milling, with its short cutting distance
ing the amount of cutting fluids. MQL consists of a mixture of per cutting edge engagement, in turning the large contact
pressurized air and oil microdroplets applied directly into the stresses common to all machining processes are combined
∗
Corresponding author. Tel.: +46 73 657 3924; fax: +46 31 772 1313.
E-mail address: bulent@chalmers.se (B. Tasdelen).
0924-0136/$ – see front matter © 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.10.027
222 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 3 ( 2 0 0 8 ) 221–231
Fig. 1 – Chip–tool interface (Lijing, 2004). In order to see the effect of oil droplets and air on the con-
tact length, the whole engagement time was divided into small
engagement intervals. This enables to clarify the lubrication
and cooling effects of MQL on the contact length.
with distances of continuous sliding that are enough to wipe
any initial contaminating lubricant films from the chip–tool
contact (Childs, 2002). 2. Experimental set-up
The lubricants act in the slightly loaded region where the
chip leaves the tool. There, they decrease the friction and The tests were performed with uncoated and TiN coated
thereby cause the contact length and the chip thickness to inserts. In order to understand the role of air and oil con-
reduce, but even at very low speeds they never penetrate the stituents of MQL, the tests were performed dry, with MQL
highest loaded area near the cutting edge; the tool–chip con- (24 ml/h oil and 125 l/min air) and with only compressed air
tact is as seen in Fig. 1 (Childs, 2002; Lijing, 2004; Trent and (125 l/min). The air is supplied from an external compressor
Wright, 2000; Childs et al., 2000). and directly fed into air drier and then either to the MQL unit
A model of lubricant penetration has been introduced by or to the external nozzle, see Fig. 3.
Williams (Childs, 2002) and is developed further in (Childs et In order to perform orthogonal turning tests, a special
al., 2000). It supposes that the existence of surface roughness insert geometry was used. The inserts have 0◦ rake angle and
in the lightly loaded region where the chips leave the tool 4◦ clearance angle. A special nozzle holder was mounted on
results in the real area of contact there being less than the the tool holder in order to direct the aerosol flow to the cut-
nominal area. Lubrication is possible when the penetration ting zone. As the thickness of the work pieces was 2.5 mm, it
length fraction (the ratio of contact length (t) to the length of was possible to use the cutting edge for two different tests,
the channels (lp)) approaches “1” and is ineffective for values for example dry and MQL, see Fig. 4. The cutting data for both
less than 0.1, see Fig. 2. Thus, a lubricant does not have to pen- coated and uncoated inserts is shown in Table 1.
etrate the whole contact: by attacking at the edge, it can reduce The main goal of the tests was to clarify the role of com-
the total contact length. Moreover, cooling of the chip results pressed air and oil droplets for different time of engagements
in increased up-curling of the chip and consequently reduc- in intermittent turning. Therefore, the work piece mate-
Intermittent
2 0.0678 5.4287
6 0.0226 5.4287
12 0.0113 5.4287
24 0.0056 5.4287
Fig. 4 – (A) Tool holder and nozzle fixture, (B) uncoated inserts, (C) schematic cutting 2D and (D) MQL nozzle direction and
schematic cutting (3D).
224 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 3 ( 2 0 0 8 ) 221–231
Fig. 5 – The work pieces with (A) two grooves and (B) six grooves.
comparison between MQL and compressed air was contin- topography evaluation of the inserts by vertical scanning inter-
ued with even shorter engagement time both with coated ferometry (VSI) shows the natural contact length (Lc) and the
and uncoated inserts. The chip morphology and the effect sliding length (Ls) for MQL and dry, as shown in Figs. 6 and 7.
of oil amount on contact length were also evaluated in the Comparison tests were performed between MQL and com-
work. pressed air for short and long engagement times. It was seen
that MQL and compressed air give the same total contact
length when cutting two and six-grooved work pieces. The
3.1. Contact length and chip analysis with uncoated earlier studies have shown that MQL and only compressed air
inserts have the same cooling effect (Tasdelen and Johanson, 2006).
The same cooling effect results in same chip up-curling radius
MQL decreased the contact length compared to dry cutting for for MQL and compressed air that may have resulted in the
both short and long engagement time of the section at inter- same contact length. However, the difference occurs in sliding
mittent turning. When the chip starts to slide on the sliding region. This difference is observed as clad material in sliding
region, the material starts hardening due to high deformation region as shown in Fig. 8. The difference is obvious when cut-
ratio in the shear zone. Due to the high temperature and fric- ting six-grooved work piece, as shown in Fig. 9. Otherwise both
tion it clads on the insert especially in this sliding region of contact length and the thickness of the clad material are the
the natural contact. The difference in contact length is mainly same for longer engagement time tests (work piece with two
seen in the sliding region. The clad material in the sliding grooves).
region is thicker for dry cutting especially when cutting the To summarize, MQL lowers the contact length compared
work piece with six grooves, see Figs. 6 and 7.The surface to dry cutting and the effect is mainly due to cooling effect
Fig. 6 – Contact length comparison between MQL and dry cutting. (A) Optical microscopy image of insert that cut work piece
with two grooves. (B) Optical microscopy image of insert that cut work piece with six grooves. (C) SEM image of insert that
cut with MQL (work piece with two grooves). (D) SEM image of the insert that cut dry (work piece with two grooves). (E) SEM
image of the insert that cut with MQL (work piece with six grooves). (F) SEM image of the insert that cut dry (work piece with
six grooves).
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 3 ( 2 0 0 8 ) 221–231 225
Fig. 7 – Tool-contact surface topography for the inserts from the tests with six-grooved work piece. (A) MQL and (B) dry.
Fig. 8 – Contact length comparison between MQL and compressed air assisted cutting. (A) Optical microscopy image of
insert that cut work piece with two grooves. (B) Optical microscopy image of insert that cut work piece with six grooves. (C)
SEM image of insert that cut with compressed air (work piece with two grooves). (D) SEM image of the insert that cut with
MQL (work piece with two grooves). (E) SEM image of the insert that cut with MQL (work piece with six grooves). (F) SEM
image of the insert that cut with compressed air (work piece with six grooves).
from air constituent in the aerosol flow. This was proven by the same plot in order to decrease the variation due to insert
having the same contact length for MQL and compressed quality.
air. However, when the engagement time of the section is One of the most important parameters that can change the
short, the lubrication of oil droplets at the grooves is obvi- contact length is the feed rate (Sadik and Lindström, 1995).
ous. The lubrication effect, which is inversely proportional to However, increasing the feed rate would cause higher forces
the thickness of clad material in the sliding region, increases or decreasing the feed rate would increase the compressive
with the increase in the number of grooves, see Fig. 9. The stress on the inserts. On the other hand, testing different cut-
summary of the measurements is given in Fig. 10. All these ting speeds will result in different chip speed, contact length
tests were performed two times; however, the test results and different amount of heat involved in the cutting zone.
that were performed on the same insert are presented on Therefore, a comparison test series were performed to see
Fig. 9 – Tool-contact surface topography of the inserts from the tests with six-grooved work piece. (A) MQL and (B)
compressed air.
226 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 3 ( 2 0 0 8 ) 221–231
Fig. 11 – Comparison between MQL and compressed air for different speeds (six grooves).
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 3 ( 2 0 0 8 ) 221–231 227
Fig. 13 – Comparison of MQL and compressed air (12 grooves). (A) Optical microscopy view. (B) SEM image of the same insert.
Fig. 15 – The contact length values for emulsion and MQL (six grooves).
228 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 3 ( 2 0 0 8 ) 221–231
Fig. 16 – Chip morphology difference (after cutting a work piece with six grooves).
are more up-curled for emulsion. The small radius of cur- have more wear resistance, a work piece with 24 grooves was
vature is also an indicator of the short contact length. The also tested. The contact length of the inserts that were tested
chips from MQL and compressed air assisted tests have almost on work pieces without grooves, with two, six grooves had
the same radius of curvature. The largest contact length that no apparent difference for MQL and compressed air cutting.
was observed on the rake face was also observed as the With 12- and 24-grooved work pieces the difference in sliding
largest radius of curvature of the chips after dry cutting. The region was more obvious, as shown in Figs. 18 and 19. Due to
other interesting observation is that chips produced in dry the friction in this sliding region, the chip has a rubbing effect
cutting have side curl radius due to difference in speed on on the insert that results in sticking of chip material on this
the inner and outer diameter of work piece, as shown in region of insert. Therefore, the thickness of this clad material
Fig. 16. The same phenomenon was not seen for other tests in this sliding region may be connected to friction. The clad
meaning that the speed is almost the same throughout the material is thicker and due to fast cooling, cracks on that clad
cutting edge during cutting. The chips produced in dry cut- material were observed at sliding region for compressed air
ting are wider than the chips produced in cutting with MQL, assisted cutting. For MQL assisted turning no cracking in the
compressed air and emulsion. The wider chips for dry cut- clad material was observed since the thickness and length of
ting is a result of side flow in the shear plane that was also that region is shorter compared to inserts that cut with com-
observed in the earlier works of the authors with conventional pressed air assistance. The summary of how contact length
inserts.
Side flow is the flow of material to the sides in the shear
plane. The higher the temperature in the shear plane the less
viscous is the material and the more side flow is seen. The
material that flows to the side makes the chips wider than
depth of cut and generally sticks on the hills of feed marks
and makes the surface finish worse.
The difference between MQL and compressed air that
resulted in different contact length was also observed in the
chip shape. The oil droplets affect the contact in the beginning
of chip formation that results in smaller radius of curvature in
the head of the chips, as shown in Fig. 17.
Fig. 18 – Comparison of insert rake face that cut 24-grooved work piece showing a thicker clad material with cracks in air
assisted cutting. (A) SEM image of the insert that cut with MQL. (B) SEM image of the insert that cut with compressed air
assistance. (C) Cracks on the clad material in sliding region of the insert.
Fig. 19 – Tool–chip contact surface topography of the coated inserts (24-grooved work piece). (A) MQL and (B) compressed air.
Fig. 21 – Comparison of MQL with low and higher amount of oil (work piece with 24 grooves).
Fig. 22 – Tool–chip contact topography of the coated inserts (24-grooved work piece). (A) MQL with 24 ml/h and (B) MQL with
70 ml/h.
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