CHAPTER 3

PROMOTION OF CHIP CURL

3.1 INTRODUCTION
Among the factors that affect the cutting performance during minimal fluid
application, tool chip contact length plays an important role owing to its effect on
friction and temperature at the tool-chip interface (Sadik et al., 1995). Low tool
chip contact length can lead to lower cutting force; lower tool wear and better
surface finish. Hence any mechanism that will lead to reduction in tool chip
contact length can bring forth better cutting performance. As revealed in literature
review, reduction in tool chip contact length can be achieved by promoting the
chip curl. Chip curl radius can be reduced by the following methods.
1. By providing chip breaker on the rake face (Shaw, 1984),
2. By using restricted contact tools (De Chiffre, 1982, Sadik et al,1995),
3. By effecting better rake face lubrication (Seah et al., 1997, Tasdelen,
2008, Suresh et al., 2009),
4. By adding free machining additives to the work material (Shaw, 1984),
5. By reducing thermal conductivity of tool (Balaji et al., 1999),
6. By increasing cutting velocity, decreasing feed and depth of cut
(EmreOzlu et al., 2009), and
7. By increasing work piece hardness (Luo et al., 1999).
In the present investigation an attempt was made to promote chip curl by
introducing a minimal high velocity pulsing slug of cutting fluid on the top side of
the chip. The presence of cutting fluid at the top side of the chip is expected to
cause contraction of the top surface of the chip which results in the bending of the
chip away from the rake face thereby reducing the tool chip contact length.
3.2 SELECTION OF WORK MATERIAL
Through hardenable AISI 4340 high strength low alloy steel was used as
work material throughout the investigation. It is a general purpose steel having
wide range of applications in automobile and allied industries by virtue of its
through hardenability, enabling it to be used in fairly large sections (Varadarajan et

34
al., 2002a). Considering its wide range of application in the industry this grade of
steel was considered as the work material in the present investigation. Workpiece
was through hardened followed by tempering to achieve hardness 45 HRC. Bars of
70mm diameters and 350 mm length with composition as in Table 1 were used in
the present investigation. In order to assure the required stiffness of
chuck/workpiece/cutting system, the ratio of cylindrical turning length to the initial
diameter of workpiece (L/D ratio) was approximately kept as 4.
Table 3.1 Composition of work piece material
C Ni Cr Mo Mn Si Fe
0.44 1.91 1.25 0.34 0.68 0.38 Rest

3.3 SELECTION OF CUTTING TOOL

Multicoated hard metal inserts with sculptured rake face geometry with the
specification SNMG 120408 MT TT5100 from Taegu Tec were used as cutting
tools in this investigation. The inserts have a multilayer CVD coating (TiN/MT-
TiCN/Al2O3) on a cemented carbide substrate. CVD coating consists of TiN for
reducing friction and a medium temperature CVD coating of TiCN for high
fracture toughness and good abrasive wear resistance. Figure 3.1 presents a
photograph of the turning tool insert. Table 3.2 gives the dimensions of various
elements of the insert. The specification of the tool insert is presented in Table 3.3.
The inserts were mounted on a pin and hole type tool holder having specification
PSBNR 2525 M12 (Figure 3.2). The resulting working tool geometry and basic
dimensions of insert and tool holder are presented in Table 3.4. The cutting tool
inserts and the tool holder were selected as per the recommendations of M/s.
Tageu Tec India (P) Limited who were extending their technical/material support
for this research work.
3.4 SELECTION OF CUTTING FLUID
Since the quantity of cutting fluid used is extremely small, a specially
formulated cutting fluid was employed in this investigation. The base was a
commercially available mineral oil. The formulation contained, in addition to
coolant and lubricant, additives such as surfactant, evaporator, emulsifier,
35
 Figure 3.1 Photograph of the insert with its design details

Table 3.2 Dimensions of the insert

Designation L d R t
SNMG 120408 MT TT5100 11.9 mm 12.7 mm 0.8 mm 4.756 mm

Table 3.3 Specification of the insert

Specification of SNMG 120408 MT TT5100 Insert
S Type of Shape
N Clearance angle.
M Tolerance.
G Grain size
12 Cutting edge length
04 Thickness
08 Corner radius
MT Medium roughing
TT5100 Grade

Table 3.4 Working tool geometry and dimensions of insert and tool holder
Angle of inclination, λs=- 6o
Orthogonal rake angle, γo=-6o
Orthogonal clearance angle, αo=6o
Auxiliary orthogonal
Working tool geometry
Clearance angle, α’o=6o
End cutting edge angle, ϕe=15o
Principle cutting edge angle, ϕ=75o
Nose radius, r=0.8 mm
Tool holder size 25 x 25 x 14.7 mm
Cutting tool stand out 50 mm

36
 Figure 3.2 Photograph of turning tool holder
stabilizer, biocide and a deodorizing agent (Varadarajan et al., 2002b). It acted as
an oil in water emulsion. Table 3.5 shows the various constituents present in the
cutting fluid formulated.
Petroleum sulphonate acts as a multifunctional additive. It can act as an
emulsifier, a rust inhibitor, a surfactant and as an EP agent. The polar nature of the
Sulphonate end of the molecule functions as a typical anionic surfactant. The tail
of the Sulphonate is made up of a hydrocarbon chain which has no charge.
Sulphonates act on the surface of oil droplets by binding at the tail. The head of the
Sulphonate has a polar charge, allowing the head to bond to water droplets. Thus
the Sulphonate can hold oil and water apart so that they can co-exist and form an
emulsion.
Ethylene glycol resists freezing due to its low freezing point and acts as a
coupling agent to increase the stability of the emulsion. The use of ethylene glycol
not only depresses the freezing point but also elevates the boiling point such that
the operating range for the heat transfer fluid is broadened on both the ends of the
temperature scale. The increase in boiling temperature is due to pure ethylene
glycol having a much higher boiling point and lower vapor pressure than pure
water. Oleic acid is an unsaturated fatty acid which is used as an emulsifying or
solubilizing agent in aerosol products. Besides serving as an agent for improving
the lubricity of the cutting fluid (agent for lowering the friction coefficient –

37
friction modifier), this compound forms an effective agent for enhancing
permeability. In water soluble cutting fluids, Triethaol Amine is used to provide
the alkalinity needed to protect the work against rusting and it acts as an anti-
oxidant. It also controls the evaporation rate of water in cutting fluid.
Table 3.5 Composition of the cutting fluid
S.No. Name of the constituent Percentage
Petroleum Sulphonate
1 15 %
(molecular weight=490 to 520)
2 Ethylene glycol 1%

3 Oleic acid 3%

4 Triethaol amine 3%

5 Alcohol Ethoxylate 2%-6%

6 Mineral oil (Paraffinic) rest

Alcohol ethoxylate is a nonionic surfactant created by adding ethylene

oxide groups to long chain (high molecular weight) alcohols. Alcohol ethoxylates
possess greater resistance to water hardness than many other surfactants. It also
acts as a secondary emulsifier which enhances the emulsification capability of the
sulfonate. It is formulated from selected aliphatic hydrocarbons and alcohol
ethoxylates are known for their biodegradability.
Mineral oils are hydrocarbons obtained during refining of crude oil. Their
properties depend on their chain length and structure. The formulation was
developed and used successfully by Vardarajan et al. (2002b) during their
investigation on turning of hardened AISI4340 Steel. The same formulation is
being tried in the present investigation also.
3.5 MINIMAL FLUID APPLICATOR
A photograph of the minimal fluid applicator used for this
investigation is shown in Figure 3.3. Figure 3.4 shows the schematic diagram of
minimal fluid applicator. The fluid applicator consists of a fuel pump (Bosh Type)
of a four cylinder compression ignition engine which is coupled to an infinitely

38
variable electric drive. The fuel pump has a plunger with helical groove which can
rotate about its axis and the degree of rotation of plunger determines the quantity
of fluid delivered per stroke. There is a provision for rotating the plunger so that
the quantity of fluid delivered per stroke can be controlled accurately. The cutting
fluid was delivered using a standard fuel injection nozzle (Bosh make) used in
compression ignition engines with a specification DN0SD151with out any
modifications. Fuel injector with this specification had a spray angle of 0o and
gave the best performance for fluid minimization applications (Philip et al., 2001).
The plunger reciprocates as the motor rotates and delivers one pulse of cutting
fluid for each revolution through the fluid injector. The pressure of the cutting
fluid at the injector before it is delivered through the nozzle can be set at any
predefined value. The fluid coming out of the injector consists of myriads of tiny
droplets, the velocity of which depends upon the pressure set at the fluid injector
nozzle. Higher the pressure, higher will be the velocity of the individual particles.

Figure 3.3 Minimal fluid application system

39
 Figure 3.4 Schematic diagram of minimal fluid applicator

Figure 3.5 Direction of fluid jets

For a given pressure at the fluid injector, a particular rate of fluid
application can be maintained irrespective of the frequency of pulsing. For
example, if the pressure at the fluid injector was maintained at P1 bar and the
injector delivers at the rate of Q ml/min at a frequency of 500 pulses/min, the same
delivery rate of Q ml/min can be maintained at a frequency of 1000 pulses/min
also. This is achieved by rotating the plunger with the helical groove in a proper
direction. The quantity delivered per pulse is equal to Q/N, where N is the
frequency of pulsing (in pulses/min). For example, the quantity of delivery per
pulse when the frequency of pulsing is 1000 pulses/min is equal to Q/1000 where
as it is equal to Q/500 when the frequency of pulsing is 500 pulses/min. Like this,
maintaining any delivery rate of cutting fluid for any frequency of pulsing is also

40
possible for a given pressure set at the injector nozzle. In short, in the fluid
application system developed it is possible to vary the pressure, frequency of
pulsing and rate of delivery independently. A specially formulated mineral oil
base cutting fluid (Varadarajan et al., 2002b) which acted as an oil in water
emulsion, as mentioned earlier was applied as a narrow pulsed slug at tool work
interface (Philip et al., 2001) and at the top side of the chip as shown in Figure 3.5.
The system can supply a pulsing slug of cutting fluid at four locations in the same
machine tool or to four separate machine tools simultaneously.
3.6 MEASUREMENT OF PROCESS PARAMETERS
Cutting force was measured using a Kistler piezoelectric dynamometer of
type 9257B. It consists of a multichannel charge amplifier (Type:5070A) as well
as a data acquisition and analysis system (DynoWare). This multi component
dynamometer facilitates dynamic and quasi-static measurement of the three
orthogonal components of cutting force. The assembly of Kistler dynamometer
and data analysis and display units is shown in Figure 3.6 and 3.7 respectively.

Figure 3.6 Photograph of Kistler dynamometer (Type 9257B)

41
 Figure 3.7 Kistler-data analysis and display system

Figure 3.8 Photograph of surface roughness tester

The surface roughness was measured using a stylus type surface roughness
tester TR100 developed by the TIME with a cut off distance of 0.8mm. Its main
features are high accuracy, wide range of application, simple operation, and stable
performance. When the sensor driven by a driver is making a linear uniform
motion along the test surface, the contact stylus which is perpendicular with the
work surface moves up and down with the work surface. Its motion is converted
into electric signals, which are amplified, filtered and transformed into digital

42
signals through an analog to digital converter. The signals are then processed by
the CPU into Ra and Rz values before being displayed on the screen. Photograph of
surface roughness tester is shown in Figure 3.8. The average roughness (Ra) is the
area between the roughness profile and its mean line, or the integral of the absolute
value of the roughness profile height over the evaluation length. Ra averages all
peaks and valleys of the roughness profile, and then neutralizes the few outlying
points so that the extreme points have no significant impact on the final results. In
the present investigations, Ra was selected to express the surface roughness.

Figure 3.9 Photograph of tool makers’ microscope

Average flank wear and tool chip contact length were measured using a tool
makers’ microscope (Metzer make) with a least count of 0.005 mm. The
photograph of Metzer tool makers’ microscope is shown in Figure 3.9. When the
relief face of a cutting tool rubs against the workpiece, flank wear occurs on this
face and this type of tool wear is caused by an abrasion mechanism and it
progresses gradually. Flank wear impairs the accuracy of the parts machined

43
because it causes deflection of the cutting tool. Flank wear is usually maximum at
the extremities of the cutting edge and in the central zone the wear land it is fairly
uniform. Flank wear land width (VBB) shown in Figure 3.10 is the criterion of tool
life according to the ISO 3685 (1993) standard. When the wear patterns formed on
relief face of cutting tool are regular, VBB =0.3 mm is the criterion of tool life, and
if the wear patterns formed on relief face of cutting tool are not regular, VBB
max=0.6 mm is considered as the criterion of tool life.

Figure 3.10 (a) Top view of crater wear and nose profile and (b) flank wear land
and notch wear of cutting tool based on ISO 3685 (ISO, 1993).

Nose area of cutting tool is where the nose wear (VBC) occurs. When severe
nose wear is formed catastrophic tool failure can occur which will bring the life of
the tool to a premature end. Due to the limitation of the existing methods, which
cannot measure the nose wear fast and accurately, only few studies have been
carried out in the past to investigate the effect of nose wear. The reason why VBB
is often used is that it can be measured in a fairly objective way while nose wear is
difficult to quantify. Fortunately time history of each of these types of wear is

44
similar. In this study average flank wear land width (VBB) was considered and
measured for quantifying tool wear.
In the metal cutting process, after the chip is formed in the shear zone, it
slides over the rake face of the tool until it leaves away from the tool. The distance
from the tool tip to where it leaves the tool is called tool chip contact length as
shown in Figure 3.11. Total tool-chip contact length consists of sticking region
adjoining the cutting edge where sticking and adhering taking place followed by
sliding region in which the chip slides over the tool rake face until it leaves the
tool. Tool chip contact length affects chip form and chip ratio, surface finish, tool
temperature, cutting force, power consumption and tool life during metal cutting
(Sadik et al., 1995). Tool-chip contact length is one of the most important factors
governing tool performance owing to its effect on the flank wear and tool
temperature. The microscopic examination of cutting tool inserts used in metal
cutting processes clearly shows superficial marks left on the cutting tool rake
surface. Hence, in this work, tool-chip contact length was estimated by measuring
the length of the rubbing marks on the insert rake face after the machining tests
with the aid of tool maker’s microscope.

Figure 3.11 Tool chip contact length

45
 Tool work thermocouple technique is widely used for measuring cutting
temperature. But this technique requires a reliable method of calibration, which is
difficult to accomplish especially when the tool is in the form of an insert.
Frequent short-circuiting by the chip complicates the measurement of thermo
e.m.f. The cutting temperature was measured using an extrapolative prediction
technique (Varadarajan et al., 2000) based on Finite Element Analysis. Two
standard K type thermocouples were planted at the interface between the cutting
tool inset and the holder symmetrically. The bottom of the insert and the two sides
were insulated for thermal isolation of the insert from the tool holder as shown in
Figure 3.12.

Figure 3.12 Location of thermocouples (Extrapolative prediction of cutting

temperature during turning, Varadarajan et al., 2000)

The temperature as indicated by the two thermocouples was measured

simultaneously 60 seconds after the commencement of cutting to achieve a steady
state condition in the insert. A correlation was developed between the nodal
temperature and the average temperature of the tool tip using a finite element
model which was validated using tool work thermo couple technique (Varadarajan
et al., 2000). This method provided a fairly accurate method of predicting cutting

46
temperature since the nodal temperatures are measured using standard
thermocouples. All measurements were repeated three times, and the average of
these three measurements was taken as the final value of tool wear, surface
roughness, and cutting force.

Figure 3.13 Photograph of experimental setup

A Kirloskar Turn Master- 35 all geared lathe was used for this research
work and the photograph of experimental setup is shown in Figure 3.13. The
specifications of lathe are as under.
Distance between centers (max) : 800 mm
Height of center : 175mm
Motor : 3 hp/2.2 Kw
Speed : 0 - 1500 rpm
Feed rate : 0 – 2mm\rev
Depth of cut : 0 – 1.25 mm
Feed drive : 1 hp DC motor

47
3.7 EFFECT OF AUXILIARY PULSING SLUG OF CUTTING FLUID

3.7.1 Experimentation

Photograph of the experimental set up is shown in Figure 3.14. A specially

formulated mineral oil base cutting fluid (Varadarajan et al., 2002b) which acted
as an oil in water emulsion, was applied as a narrow pulsing slug at tool work
interface (Philip et al., 2001) and at the top side of the chip as shown in Figure
3.15. An eight run experiment was designed based on Taguchi’s Technique
(Lochner and Matar, 1990) and the design matrix is shown in Table 3.6. The
process parameters such as rate of fluid application, frequency of pulsing,
composition and direction of fluid application were varied at two levels as shown
in Table 3.7. For the auxiliary jet, the rate of fluid application was kept at 2ml/min,
the frequency of pulsing at 600 pulses/min and the composition of the cutting fluid
was kept as 10% oil and the rest water (Philip et al., 2001). The cutting velocity
was maintained at 80m/min, feed at 0.1mm/rev, the depth of cut at 1.25mm and the
pressure at fluid injector at 80 bar (Varadarajan et al., 2002a). Cutting experiments
were conducted with three replications.

Figure 3.14 Experimental set up

48
 Figure 3.15 Direction of fluid application
The results are presented in Table 3.8. The set of levels of input parameters
to achieve minimum cutting force, surface roughness, tool wear, tool chip contact
length and cutting temperature was determined using Qualitek-4 software and
presented in Table 3.9. Table 3.10 presents the percentage significance of the
direction of fluid application on the performance.
A variable speed test, a variable feed test and a tool life test were conducted
to compare the performance during dry turning, wet turning, conventional turning
with minimal fluid application and turning with minimal fluid application with an
auxiliary jet in the optimised location (Table 3.9). The feed was kept at 0.1
mm/rev, depth of cut was kept at 1.25 mm and the cutting velocity was varied
from 80 to 120 m/min at five steps during the variable speed test. The cutting
force, surface roughness, tool wear, tool chip contact length and cutting
temperature were measured during each trial and results are presented in Figures
3.16 (a), (b), (c) and (d). During the variable feed test, the cutting velocity was
kept at 80 m/min, depth of cut at 1.25 mm and the feed was varied from 0.04 to
0.08 mm/rev at five steps. The results are summarised in Figures 3.17 (a), (b), (c)
and (d). A tool life test was conducted and during the tool life test, the cutting
velocity was kept at 80 m/min, feed at 1mm/rev and the depth of cut at 1.25 mm.
Figure 3.18 compares the variation of flank wear during dry turning, wet turning,
conventional turning with minimal fluid application and turning with minimal fluid
application along with an auxiliary fluid jet.

49
 Table 3.6 Design matrix for the eight run experiment
Rate of
Frequency Minimal Direction
fluid
Conditions of pulsing cutting fluid of fluid
application
(pulses/mim) composition application
(ml/min)
1 5 300 C1 D1
2 5 300 C2 D2
3 5 600 C1 D2
4 5 600 C2 D1
5 10 300 C1 D2
6 10 300 C2 D1
7 10 600 C1 D1
8 10 600 C2 D2

Table 3.7 Process variables and their levels

Factor Level 1 Level 2
Rate of fluid
5 10
application (ml/min)
Frequency of pulsing of
minimal cutting 300 600
fluid(pulses/mim)
Minimal cutting fluid 20% Oil + rest 10% Oil + rest
Composition water(C1) water(C2)
Auxiliary Jet at Top
Direction of fluid No Auxiliary Jet at Top
side of chip
application side of chip (D2)
(D1)

50
 Table 3.8 Observations during the cutting experiments
Cutting Surface Tool-chip Tool
Conditions Force Cutting Temp(ºC) Finish contact wear(average)
(N) (µm) length(mm) (mm)
1 142.5 202 1.71 0.22 0.03
2 154 212 2.08 0.26 0.06
3 152 228 2.04 0.30 0.05
4 149 202 1.88 0.22 0.04
5 155 227 2.11 0.30 0.05
6 146 205 1.91 0.22 0.05
7 147 218 1.93 0.24 0.04
8 156 216 2.19 0.28 0.08

Table 3.9 Levels of operating parameters for achieving optimum performance

Factor Optimum Level
Rate of fluid application (ml/min) 5
Frequency of pulsing of minimal
300
cutting fluid (pulses/mim)
Minimal cutting fluid composition 20% Oil+ rest water
Tool Work Interface+
Direction of fluid application
Top side of chip

51
Table 3.10 Percentage significance of direction of fluid application on cutting
performance
Performance Parameters % Significance
Cutting force 76.96
Cutting Temperature 49.08
Surface finish 71.6
Tool Wear 52.86
Tool chip contact length 86.49

250

200
Dry
Cutting Force (N)

150
Wet
100
MFA

50
MFA with auxiliary
cutting fluid slug
0
80 90 100 110 120
Cutting Velocity (m/min)

Figure 3.16 (a) Variation of cutting force with cutting velocity during variable
speed test (Feed rate=0.1mm/rev, Depth of cut= 1.25mm, Pressure at fluid
injector=80 bar, Rate of fluid application=5ml/min, Frequency of
pulsing=300pulses/min, Composition of cutting fluid=20%+rest water)

52
 600

Average Cutting Temperature (oC)

500
Dry
400

300 Wet

200 MFA

100 MFA with auxiliary

cutting fluid slug
0
80 90 100 110 120
Cutting Veocity(m/min)

Figure 3.16 (b) Variation of average cutting temperature with cutting velocity
during variable speed test ((Feed rate=0.1mm/rev, Depth of cut= 1.25mm, Pressure
at fluid injector=80 bar, Rate of fluid application=5ml/min, Frequency of
pulsing=300pulses/min, Composition of cutting fluid=20%+rest water)

4.5
4
Surface Roughness Ra (µm)

3.5
Dry
3
2.5
Wet
2
1.5 MFA
1
0.5 MFA with auxiliary
cutting fluid slug
0
80 90 100 110 120
Cutting Velocity (m/min)

Figure 3.16 (c) Variation of surface finish with cutting velocity during variable
speed test ((Feed rate=0.1mm/rev, Depth of cut= 1.25mm, Pressure at fluid
injector=80 bar, Rate of fluid application=5ml/min, Frequency of
pulsing=300pulses/min, Composition of cutting fluid=20%+rest water)

53
 0.45
0.4

Tool Chip Contact Length (mm)

0.35
Dry
0.3
0.25
Wet
0.2
0.15 MFA
0.1
MFA with auxiliary
0.05
cutting fluid slug
0
80 90 100 110 120
Cutting Velocity (m/min)

Figure 3.16 (d) Variation of tool chip contact length during variable speed test.
(Feed rate=0.1mm/rev, Depth of cut= 1.25mm, Pressure at fluid injector=80 bar,
Rate of fluid application=5ml/min, Frequency of pulsing=300pulses/min,
Composition of cutting fluid=20%+rest water)

250

200
Dry
Cutting Force (N)

150
Wet

100
MFA

50
MFA with auxiliary
cutting fluid slug
0
0.04 0.05 0.06 0.07 0.08
Feed rate(mm/rev)

Figure 3.17 (a) Variation of cutting force with cutting velocity during variable feed
test. (Cutting Velocity= 80m/min, Depth of cut= 1.25mm, Pressure at fluid
injector=80 bar, Rate of fluid application=5ml/min, Frequency of
pulsing=300pulses/min, Composition of cutting fluid=20%+rest water)

54
 400

Average Cutting Temperature (oC)

350

300
Dry
250

200 Wet

150
MFA
100

50 MFA with auxiliary

cutting fluid slug
0
0.04 0.05 0.06 0.07 0.08
Feed rate (mm/rev)

Figure 3.17 (b) Variation of average cutting temperature with feed during variable
feed test. (Cutting Velocity= 80m/min, Depth of cut= 1.25mm, Pressure at fluid
injector=80 bar, Rate of fluid application=5ml/min, Frequency of
pulsing=300pulses/min, Composition of cutting fluid=20%+rest water)

4.5

4
Surface Roughness Ra (µm)

3.5

3 Dry

2.5 Wet

MFA
2
MFA with auxiliary
1.5 cutting fluid slug

1
0.04 0.05 0.06 0.07 0.08
Feed rate(mm/rev)

Figure 3.17 (c) Variation of surface finish with feed during variable feed test.
(Cutting Velocity= 80m/min, Depth of cut= 1.25mm, Pressure at fluid injector=80
bar, Rate of fluid application=5ml/min, Frequency of pulsing=300pulses/min,
Composition of cutting fluid=20%+rest water)

55
 0.45

Tool Chip Contact Length (mm)

0.4

0.35

0.3 Dry

0.25 Wet

0.2 MFA

0.15 MFA with auxiliary

cutting fluid slug
0.1
0.04 0.05 0.06 0.07 0.08
Feed rate(mm/rev)

Figure 3.17 (d) Variation of tool chip contact length during variable feed test.
(Cutting Velocity= 80m/min, Depth of cut= 1.25mm, Pressure at fluid injector=80
bar, Rate of fluid application=5ml/min, Frequency of pulsing=300pulses/min,
Composition of cutting fluid=20%+rest water)

0.35

0.3
Flank Wear Vb(mm)

0.25 Dry

0.2
Wet
0.15
MFA
0.1

0.05 MFA with auxiliary

cutting fluid slug
0
30 60 90 120 150
Time (sec)

Figure 3.18 Variation of flank wear during different turning methods in the
optimized condition. (Cutting Velocity= 80m/min, Feed rate=0.1mm/rev, Depth of
cut= 1.25mm, Pressure at fluid injector=80 bar, Rate of fluid application=5ml/min,
Frequency of pulsing=300pulses/min, Composition of cutting fluid=20%+rest
water)

56
3.7.2 Results and Discussion
Lower cutting force, lower surface roughness, lower tool wear and lower
cutting temperature were observed when an auxiliary pulsing slug of cutting fluid
was introduced on the top side of the chip along with a minimal slug of cutting
fluid at the tool work interface as in conventional minimal fluid application
scheme.
The cutting fluid droplets coming from the auxiliary jet falls on the top side
of the chip and when they evaporate, they take away the latent heat of vaporisation
from the surface of the chip which cools it leading to its contraction. But the
bottom surface which is in contact with tool rake face is still hot and tries to
elongate. This results in the bending of the chip away from the tool rake face
thereby reducing the tool chip contact length as in Figures 3.19(a) and 3.19(b).
A chemical phenomenon can also occur on the top side of the chip which
leads to embrittlement or weakening of chip surface due to Rebinder effect
(Astakhov, 2010). During formation of chip, myriads of micro cracks are formed
on the top side of the chip. The nascent surfaces at the crack tip can heal leading to
the formation of micro weldments in the absence of any dopements as shown in
Figure 3.20 (a). The formation of micro weldments strengthens the top side of the
chip and decrease its tendency to bend away from the rake face. But when the fluid
particles from the auxiliary jet fall on the crack tips, they dope the nascent surfaces
formed by acting as a dielectric as shown in Figure 3.20 (b). This prevents the
formation of micro weldment leading to the weakening of the chip and it bends
away from the rake face and breaks (Astakhov, 2010). This mechanism leads to
the reduction in tool-chip contact length. The reduction in tool chip contact length
can bring forth better cutting performance in terms of reduced cutting force,
reduced tool wear and improved surface finish (De Chiffre, 1997).
The minimal fluid jet is characterized by myriads of tiny high velocity fluid
particles as decided by the pressure at the fluid nozzle (Philip et al., 2001). When
the fluid jet was applied at the tool work interface, these fluid particles reach the
root of the chip. Extreme pressure and temperature conditions that exist near the

57
 Fig. 3.19(a) Without Auxiliary jet Fig. 3.19 (b) With auxiliary jet
Figure 3.19 (a) Contact of chip on tool rake face in the absence of the auxiliary jet
(Tool-chip contact length=L1)
Figure 3.19 (b) Contact of chip on tool rake face when the auxiliary jet was applied
(Tool-chip contact length = L2), L2<L1

Fig. 3.20 (a) Fig. 3.20 (b)

Figure 3.20 (a) Formation of micro weldment on the top side of the chip in the
absence of cutting fluid leading to strengthening of the chip.
Figure 3.20 (b) Cutting fluid particles acting as dopements to prevent formation of
micro weldment leading to weakening of the chip. (L3>L4)

root of the chip may cause the decomposition of the cutting fluid. These products
of the decomposition can penetrate on to the work surface near the root of the chip
which can lead to embrittlement effect as in Figure 3.21 similar to hydrogen
embrittlement (Astakhov, 2010). This embrittlement may lead to the formation of
a number of microcracks on the work surface adjacent to the root of the chip which
can act as stress concentrators.
The products of decomposition of the cutting fluid get absorbed on the
surface and prevent healing of the cracks. This embrittlement action of the cutting

58
fluid reduces the strain at fracture of the work material. This action is based on
Rebinder effect (Astakhov, 2010) which involves alteration of physical properties
by changing surface energy through a physio-chemical process. The increase in the
embrittlement of the layer being removed reduces the work of plastic deformation
needed for the formation of chip. Ultimately this leads to the reduction in cutting
force and tool wear as evident from Figures 3.16, 3.17 and 3.18.
The work surface near the root of the chip with microcracks forms the back
side of the chip as the chip is generated which starts moving over the rake face as
shown in Figure 3.22. The product of the decomposition of the cutting fluid can
penetrate in to these microcracks and can prevent the healing of the microcracks.
As the chip moves over the rake face, these particles in the microcracks can form a
layer in between the tool rake face and the chip.

Figure 3.21 Formation of microcracks near the tool tip when the chip formation
begins.

Figure 3.22 Microcracks bearing product of decomposition of cutting fluid at the

back side of the chip that promotes rake face lubrication.

59
 XRD analysis was carried out on the back side of the chip to identify
chemical compounds if any formed during turning with minimal fluid. Figure
3.23(a) presents the results of XRD analysis during conventional wet turning and
that during turning with minimal fluid application is available in Figure 3.23(b).
From the results of XRD analysis shown in Figure 3.23(a), it was observed that
two peaks, one at 2θ=20.5o and another one at 2θ=51o were recorded during
turning with minimal fluid application. But during wet turning only one peak at
2θ=51o corresponding to iron was recorded. As per JCPDS CARD No 30-665, a
diffraction angle of 2θ=51o corresponds to iron and 2θ=20.5o corresponds to a
compound containing sulfur. Compound of sulfur may be one of the products of
decomposition of cutting fluid which contains petroleum sulfonate as friction
modifier. To substantiate this finding, ESCA analysis was also performed at the
back side of the chip and the results are shown in Figures 3.24 (a) and 3.24(b). A
feeble peak at 150 to 169 eV is recorded in ESCA analysis during minimal fluid
application which corresponds to the presence of a complex sulfur compound.
Such a peak is totally absent in the ESCA analysis results during conventional wet
turning. This clearly indicates that cutting fluid application in the form of a high
velocity narrow pulsing slug at the tool work interface can promote the formation
of a complex compound at the back side of the chip. The presence of the
compound layer at the tool chip interface can act as a dielectric preventing the
surface interaction between the back side of the chip and tool rake face which
prevents the sticking of the chip on to the rake face and improves rake face
lubrication. Due to this the friction condition at the tool chip interface turns from
sticking to one of sliding which brings forth reduction of cutting force. The
reduction in cutting force leads to reduction in tool wear, reduction in cutting
temperature and improvement in surface finish as evident from Figures 3.16, 3.17
and 3.18.
The pulsing nature of the slug of the cutting fluid also contributes to better
rake face lubrication which can lead to reduction in tool chip contact length (Seah
et al, 1997) and hence better cutting performance. It is reported that the frictional

60
 Fig. 3.23 (a)Wet Turning Fig.3.23(b) Turning with Minimal Fluid
Application

Figure 3.23 (a,b) XRD analysis at the back side of the chip during wet turning and
turning wih minimal fluid application respectively.

Fig. 3.24 (a)Wet Turning Fig.3.24 (b) Turning with Minimal

Fluid Application

Figure 3.24 (a,b) ESCA analysis at the back side of the chip during wet turning
and turning wih minimal fluid application respectively

61
forces between the sliding surfaces can be reduced by rapidly fluctuating the width
of the lubricant filled gap separating them (Uzi Landman, 1998). When a pulsing
slug of cutting fluid is applied at the tool work interface, the width of the lubricant
filled gap between the tool and the chip fluctuates with the frequency of pulsing of
the fluid slug. The width will be maximum when the fluid slug falls at the gap and
will be minimum when no cutting fluid falls in the gap during the pulsing cycle.
This process continues as the fluid particles fall on the gap between the tool and
the chip intermittently. This pulsing slug of cutting fluid can bring forth a
fluctuating width of cutting fluid between the tool and the chip and results in
reduction of friction in the tool-chip interface which intern reduces the tool-chip
contact length and leads to better cutting performance.
Figures 3.25 (a), (b), (c) and (d) present the SEM photograph of worn
inserts during dry turning, wet turning, conventional minimal fluid application and
minimal fluid application with an auxiliary jet. It is seen that the tool wear is
minimum during minimal fluid application with an auxiliary jet. This is mainly
due to the weakening of the region near the root of the chip due to Rebinder effect
and promotion of chip curl as described earlier. This indicates that the minimal
fluid application assisted by an auxiliary jet of cutting fluid at the top side of the
chip can offer improvement in cutting performance.

Figure 3.25 (a) SEM photograph of tool wear during dry turning (Cutting
Velocity=80 m/min, Feed rate= 0.1 mm/rev, Depth of cut=1.25 mm)

62
Figure 3.25 (b) SEM photograph of tool wear during wet turning. (Cutting
Velocity=80 m/min, Feed rate= 0.1 mm/rev, Depth of cut=1.25 mm)

Figure 3.25 (c) SEM photograph of tool wear during conventional minimal fluid
application. (Cutting Velocity=80 m/min, Feed rate= 0.1 mm/rev, Depth of
cut=1.25 mm)

Figure 3.25 (d) SEM photograph of tool wear during minimal fluid application
with an auxiliary jet of cutting fluid. (Cutting Velocity=80 m/min, Feed rate= 0.1
mm/rev, Depth of cut=1.25 mm)

63
 During normal minimal fluid application a minimal fluid jet is applied at the
tool work interface alone and the improvement in cutting performance is due to the
better lubrication at the tool-chip interface due to the absorbed products of
decomposition of the cutting fluid on the back side of the chip as described earlier.
But when an auxiliary pulsing slug of cutting fluid was applied at the top side of
the chip, two mechanisms come in to action namely bending of the chip away from
the rake face and the better lubrication at the tool chip interface. Better cutting
performance observed when the auxiliary jet was used may be due to the
simultaneous influence of these two mechanisms.
3.8 EFFECT OF AUXILIARY PULSING SLUG OF WATER
In the previous work, a pulsing slug of cutting fluid was applied on the top
side of the chip during hard turning with minimal fluid application in order to
promote chip curl by cooling the top side of the chip and by promoting Rebinder
effect. It is evident from the literatures that the use of water as coolant and
lubricant is a new cooling and lubricating technology which can alleviate problems
related to pollution and ensure a green environment on the shop floor.
Furthermore, cost of cutting fluid during machining with minimal fluid application
can be further reduced by replacing the emulsified cutting fluid by high velocity
pulsing slug of water which has high thermal capacity and better cooling action
(Wang et al., 1997). In the present investigation an attempt was made to apply a
pulsing slug of water in the place of pulsing slug of cutting fluid.
3.8.1 Experimentation
A specially formulated mineral oil base cutting fluid (Varadarajan et al.,
2002b) was applied at the tool work interface in the form of a narrow pulsed slug
as in the previous case. The rate of fluid application was kept at 5 ml/min, the
frequency of pulsing at 300 pulses/min and the composition of the cutting fluid
was kept as 20% oil and the rest water. A pulsing slug of pure water was applied
on the top side of the chip as shown in Figure 3.26. The cutting velocity, feed and
the depth of cut were maintained at 80 m/min, 0.1 mm/rev, and 1.25 mm
respectively. The pressure at the fluid injector was maintained as 80 bar

64
(Varadarajan et al., 2002b). The fluid application parameters of the water jet were
varied at two levels as shown in Table 3.11. An eight run experiment was designed
and the design matrix is shown in Table 3.12. Experiments were performed with
two replications.
Table 3.11 Input parameters and level
Water jet parameters Level 1 Level 2
Pressure of jet (Bar) 20 40
Frequency of pulsing (pulses/min) 300 600
Rate of application (ml/min) 5 10

Figure 3.26 Application of pulsing slugs of pure water on the top side of the chip
Table 3.12 Design matrix
Pressure at Rate of
Frequency
Experiment the fluid water jet
of pulsing
Trial injector application
(pulses/min)
(Bar) (ml/min)
1 20 300 5
2 20 300 10
3 20 600 5
4 20 600 10
5 40 300 5
6 40 300 10
7 40 600 5
8 40 600 10

65
 The observations during experiments are presented in Table 3.13. Qualitek-
4 software was used to determine a set of levels of input parameters to obtain
minimum cutting force, surface roughness, tool wear, tool chip contact length and
cutting temperature and the results are summarised in Table 3.14
A variable speed test, a variable feed test and tool life test were conducted
to compare the performance of minimal fluid application in the presence of an
auxiliary slug of pure water. During the variable speed test, feed was kept at
0.1mm/rev, depth of cut was kept at 1.25 mm and the cutting velocity was varied
from 80 to 120 m/min at five levels. During each trial, the cutting force, surface
roughness, tool wear, tool chip contact length and cutting temperature were
measured and results are presented in Figures 3.27a, 3.27b, 3.27c and 3.27d. The
cutting velocity was kept at 80 m/min, depth of cut at 1.25 mm and the feed was
varied from 0.04 to 0.08 mm/rev at five levels during the variable feed test. The
results are presented in Figures 3.28a, 3.28b, 3.28c and 3.28d. During the tool life
test, the cutting velocity, feed and the depth of cut were kept at 80 m/min,
1mm/rev and 1.25 mm respectively. The variation of flank wear during tool life
test for the two cases is compared in Figure 3.29.
3.8.2 Results and Discussions
It is observed that the cutting performance was better during turning with
minimal fluid application with an auxiliary pulsing slug of pure water at the top
side of the chip. The pulsing slug of water is to be applied at a frequency of 600
pulses/min at a rate of 10 ml/min with a pressure of 40 bar maintained at the fluid
applicator.
When the water droplets from the auxiliary slug of water fall on the top side
of the chip, they take away the latent heat of vaporization from the top surface of
the chip and cool it. This leads to the contraction of the top surface of chip. But the
bottom surface of chip which is in contact with tool rake face is still hot and tends
to elongate. This unequal cooling on the top and the bottom surfaces of chip results
in the bending of the chip away from the tool rake face thereby reducing the tool
chip contact length.

66
 It is observed that, the frequency of pulsing at a higher level
(600pulses/min) favored better cutting performance. When the pulsing frequency
is increased, the quantity of fluid delivered per pulse decreases for a fixed rate of
fluid application. For example, if the rate of fluid application was kept at ‘Q’
ml/min and the frequency of pulsing was maintained as N pulses/min, the quantity
of fluid delivered/pulse = Q/N. When the rate of fluid application was maintained
as q but the frequency of pulsing is made 2N, the quantity of fluid delivered per
pulse = Q/2N which is half the quantity of fluid delivered per pulse when the
frequency of pulsing was kept as N. When the quantities of fluid delivered per
pulse decrease, the individual size of fluid droplets will be small and these leads to
the presence of more number of droplets and hence increase in the surface area.
This increase in surface area results in enhanced evaporative heat transfer from the
top surface of the chip and chip tends to bend away from the tool rake face more
readily leading to the reduction in tool chip contact length and associated
improvement in cutting performance. But a certain minimum size of water droplet
is to be maintained and if the individual size of water droplet is too small they will
not have enough kinetic energy to reach and strike on the top surface of the chip
and even there is a possibility of their evaporating before they could reach the top
side of the chip. It appears that a rate of fluid application of 10 ml/min is the
optimum rate of fluid application for maintaining the requisite minimum size of
fluid droplets.
Presence of water droplet on the top side of the chip can also lead to
weakening of chip surface due to Rebinder effect (Astakho, 2010). Micro cracks
are formed on the top side of the chip during the chip formation. The nascent
surfaces of the cracks can heal and form micro weldments. The formation of micro
weldments increases the strength of the top side of the chip and resists the bending
of chip away from the rake face. But when the water particles fall on the micro
crack tips, they dope the nascent surfaces of the micro crack and prevent the
formation of micro weldments. This leads to the weakening of the chip and it
bends away from the rake face and reduces the tool chip-contact length. The

67
reduction in tool chip contact length can bring forth better cutting performance in
terms of reduced cutting force, reduced tool wear and improved surface finish
(Chiffre, 1982).
Table 3.13 Observations during the experiment
Cutting Surface Tool-chip Tool
Cutting
Conditions Force Finish contact wear(average)
Temp(ºC)
(N) (µm) length(mm) (mm)
1 139 174 0.68 0.24 0.06
2 143 179 0.72 0.26 0.08
3 138 172 0.64 0.24 0.07
4 141 169 0.66 0.3 0.05
5 137 164 0.60 0.25 0.08
6 139 163 0.58 0.24 0.05
7 135 167 0.54 0.27 0.04
8 136 157 0.52 0.22 0.05

Table 3.14 Levels of operating parameters for optimum performance

Factor Optimum Level
Pressure of water jet Level 2 (40 Bar)
Frequency of pulsing Level 2 (600 pulses/min)
Rate of water jet application Level 2 (10 ml/min)

SEM photographs of worn inserts during dry turning, conventional wet

turning, turning with conventional minimal fluid application, turning with minimal
fluid application in the presence of an auxiliary pulsing slug of cutting fluid and
turning with minimal fluid application in the presence of an auxiliary pulsing slug
of pure water are shown in Figure 3.30(a), 3.30(b), 3.30(c), 3.30(d) and 3.30(e)
respectively. The corresponding tool wear are compared in Figure 3.30 (f). It is
seen that the tool wear is minimum during minimal fluid application in the
presence of an auxiliary pulsing slug of pure water.

68
 160

140

120
Cutting Force (N)

100 Pulsing slug of cutting

fluid on the top side of
80 the chip
Pulsing slug of water
60 on the top side of the
chip
40

20
80 90 100 110 120
Cutting Velocity (m/min)

Figure 3.27 (a) Variation of cutting force with cutting velocity during water slug
assisted minimal fluid application and cutting fluid slug assisted minimal fluid
application (Feed=0.1 mm/rev, DOC=1.25 mm)

300
Average Cutting Temperature (oC)

250

200
Pulsing slug of cutting
150 fluid on the top side of
the chip
100 Pulsing slug of water
on the top side of the
50 chip

0
80 90 100 110 120
Cutting Veocity(m/min)

Figure 3.27 (b) Variation of average cutting temperature with cutting velocity
during water slug assisted minimal fluid application and cutting fluid slug assisted
minimal fluid application (Feed=0.1 mm/rev, DOC=1.25 mm)

69
 2.5

Surface Roughness Ra (µm) 2

1.5 Pulsing slug of cutting

fluid on the top side of
the chip
1
Pulsing slug of water
on the top side of the
0.5 chip

0
80 90 100 110 120
Cutting Velocity (m/min)

Figure 3.27 (c) Variation of surface roughness with cutting velocity during water
slug assisted minimal fluid application and cutting fluid slug assisted minimal fluid
application (Feed=0.1 mm/rev, DOC=1.25 mm)

0.3
Tool Chip Contact Length (mm)

0.25

0.2
Pulsing slug of cutting
0.15 fluid on the top side of
the chip
0.1 Pulsing slug of water
on the top side of the
0.05 chip

0
80 90 100 110 120
Cutting Velocity (m/min)

Figure 3.27 (d) Variation of tool chip contact length with cutting velocity during
water slug assisted minimal fluid application and cutting fluid slug assisted
minimal fluid application (Feed=0.1 mm/rev, DOC=1.25 mm)

70
 145
140
Cutting Force (N) 135
130
Pulsing slug of cutting
125
fluid on the top side of
120 the chip
115 Pulsing slug of water
on the top side of the
110
chip
105
100
0.04 0.05 0.06 0.07 0.08
Feed rate(mm/rev)

Figure 3.28 (a) Variation of cutting force with feed during water slug assisted
minimal fluid application and cutting fluid slug assisted minimal fluid application
(Cutting velocity=80 m/min, DOC=1.25 mm)

200
Average Cutting Temperature (oC)

180
160
140
120 Pulsing slug of cutting
100 fluid on the top side of
the chip
80
Pulsing slug of water
60
on the top side of the
40 chip
20
0
0.04 0.05 0.06 0.07 0.08
Feed rate (mm/rev)

Figure 3.28 (b) Variation of average cutting temperature with feed during water
slug assisted minimal fluid application and cutting fluid slug assisted minimal fluid
application (Cutting velocity=80 m/min, DOC=1.25 mm)

71
 1.85

1.8
Surface Roughness Ra (µm)
1.75

1.7 Pulsing slug of cutting

fluid on the top side of
1.65 the chip
Pulsing slug of water
1.6 on the top side of the
chip
1.55

1.5
0.04 0.05 0.06 0.07 0.08
Feed rate(mm/rev)

Figure 3.28 (c) Variation of surface roughness with feed during water slug assisted
minimal fluid application and cutting fluid slug assisted minimal fluid application
(Cutting velocity=80 m/min, DOC=1.25mm)

0.18
0.16
Tool Chip Contact Length (mm)

0.14
0.12
Pulsing slug of cutting
0.1
fluid on the top side of
0.08 the chip
0.06 Pulsing slug of water
on the top side of the
0.04 chip
0.02
0
0.04 0.05 0.06 0.07 0.08
Feed rate(mm/rev)

Figure 3.28 (d) Variation of tool chip contact length with feed during water slug
assisted minimal fluid application and cutting fluid slug assisted minimal fluid
application (Cutting velocity=80 m/min, DOC=1.25 mm)

72
 0.25

Flank Wear Vb(mm) 0.2

0.15 Pulsing slug of cutting

fluid on the top side of
the chip
0.1
Pulsing slug of water
on the top side of the
0.05 chip

0
30 60 90 120 150
Time (sec)

Figure 3.29 Comparison of flank wear during turning with minimal fluid
application in the presence of a pulsing slug of pure water and a pulsing slug of
cutting fluid on the back side of the chip

Figure 3.30 (a) SEM photograph of tool wear during dry turning (Cutting
velocity=80 m/min, Feed= 0.1 mm/rev, DOC=1.25 mm, Vb,avg= 0.26 mm, time of
cut=150 sec)

73
Figure 3.30 (b) SEM photograph of tool wear during conventional wet turning
(Cutting velocity=80 m/min, Feed= 0.1 mm/rev, DOC=1.25 mm, Vb,avg= 0.22 mm,
time of cut=150 sec)

Figure 3.30 (c) SEM photograph of tool wear during turning conventional minimal
fluid application (Cutting velocity=80m/min, Feed= 0.1 mm/rev, DOC=1.25 mm,
Vb,avg= 0.21 mm, time of cut=150 sec)

74
Figure 3.30 (d) SEM photograph of tool wear during turning with minimal fluid
application in the presence of an auxiliary slug of cutting fluid on the top side of
the chip (Cutting velocity=80 m/min, Feed= 0.1 mm/rev, DOC=1.25mm, Vb,avg=
0.2 mm, time of cut=150 sec)

Figure 3.30 (e) SEM photograph of tool wear during turning with minimal fluid
application in the presence of an auxiliary slug of pure water on the top side of the
chip (Cutting velocity=80 m/min, Feed= 0.1 mm/rev, DOC=1.25 mm, Vb,avg= 0.19
mm, time of cut 150=sec)

75
 0.3

0.25
Average Flank Wear, Vb (mm)

0.2

0.15

0.1

0.05

0
Dry Turning Wet Turning Conventional MFA with a MFA with a
Minimal fluid pulsing slug of pulsing slug of
application cutting fluid water
(MFA)

Figure 3.30 (f) Comparison of tool wear during dry turning, wet turning, turning
with minimal fluid application, turning with minimal fluid application in the
presence of auxiliary slug of cutting fluid and turning with minimal fluid
application in the presence of auxiliary slug of water (Cutting velocity=80 m/min,
Feed= 0.1 mm/rev, DOC=1.25 mm, cutting time = 120 sec)

Figure 3.31 Comparison of chip samples during dry turning, wet turning, turning
with minimal fluid application and turning with minimal fluid application with an
auxiliary water jet (Cutting velocity=80 m/min, Feed= 0.1 mm/rev, DOC=1.25
mm)

76
 Figure 3.31 presents a comparison of chip forms obtained during dry, wet,
conventional minimal fluid application and minimal fluid application with an
auxiliary pulsing slug of pure water and minimal fluid application with an
auxiliary pulsing slug of cutting fluid. It was observed that coiled chips were
formed in all cutting conditions except dry turning. However, more tightly coiled
chip was obtained during minimal fluid application with an auxiliary pulsing slug
of water applied at the top side of chip. This indicates that the minimal fluid
application assisted by an auxiliary slug of water on the top side of the chip can
promote chip curl and improve the cutting performance.
It is observed that when an auxiliary pulsing slug of cutting fluid was
applied on the top side of chip, there was improvement in the cutting performance.
There was further improvement in cutting performance when the pulsing slug of
cutting fluid was replaced by a pulsing slug of pure water
3.9 SUMMARY
1. The presence of an additional high velocity pulsing slug of cutting fluid
on the top side of the chip can enhance cutting performance during hard turning
with minimal fluid application.
2. The presence of an auxiliary high velocity pulsing slug of water on the
top side of the chip in the place of a slug of cutting fluid can further enhance the
cutting performance during hard turning with minimal fluid application.
3. Application of pulsing slug of water at the top side of the chip forms an
economical and viable performance enhancer during hard turning with minimal
fluid application. This simple approach can be easily adopted on the shop floor
without the need for any major modification on the existing set up and can be used
as an effective means of improving tool life and achieving better cutting
performance.

77