Dry and MQL Milling of AISI 1045 Steel with Vegetable and Mineral-Based Fluids

Abstract

The use of mineral-based cutting fluids in machining has the drawback of affecting the environment and industries are under pressures to reduce its use in favor of cleaner productions. In this regard, the vegetal-based cutting fluids can be a superior alternative, provided they improve the technical outcomes. In the milling process, dry cutting is commonly performed, however, the application of cutting fluids using the minimum quantity of lubricant (MQL) method has proven advantageous when compared with dry machining. Furthermore, in the midst of the availability of several cutting fluids in the market, the testing of their individual performance can ascertain their potential and effectiveness for a particular application. This study examined the performances of two vegetable-based and one mineral-based oils applied by the MQL method, followed by their comparison with dry cutting amid end milling of AISI 1045 steel with TiAlN-coated cemented carbide inserts. The cutting temperature, machining forces, power consumption, workpiece surface roughness, tool life, and tool wear mechanisms were chosen as the output parameters. The experiments were conducted using two cutting speeds (150 and 200 m/min) and feed rates (0.07 and 0.14 mm/tooth), and constant axial (1 mm) and radial depths of the cut (25 mm). The temperature was measured using a K-type thermocouple soldered to the part and an infrared camera. The power was monitored with a Fluke 435 energy analyzer, and the machining force components with a Kistler dynamometer. The worn inserts were inspected under a scanning electron microscope (SEM) to analyze the tool wear mechanism. The MQL-assisted application of the cutting fluids notably lowered the cutting temperature and increased the tools’ lives. However, the cutting fluids did not reflect any significant effect on the machining force, power consumption, or surface roughness. Among all the analyzed cutting conditions, the abrasive wear mechanism dominated, damaging the cutting edges, flank, and rake surfaces of the cutting tools. In addition, adhesive and diffusion wear mechanisms were also observed.

Keywords

• end milling
• dry machining
• MQL
• vegetable- and mineral-based oils
• tool life
• machining temperature