A Novel Experimental Test Bench to Investigate the Effects of Cutting Fluids on the Frictional Conditions in Metal Cutting

Lakner, Thomas; Hardt, M.

doi:10.3390/jmmp4020045

Cited by 9 publications

(4 citation statements)

References 38 publications

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“…This choice was influenced by its extensive use in highly stressed components, such as crankshafts in critical industrial applications. This type of steel possesses outstanding mechanical properties in terms of high strength (≥1000 MPa) and toughness [28]. As for the balls, they were produced from tungsten carbide with 6% cobalt (Co).…”

Section: Materials and Characterisationmentioning

confidence: 99%

“…Furthermore, Lakner et al [28] shifted their focus to the influence of plastic deformation and subsequent thermal softening as key factors in diminishing the coefficient of friction (COF). The research conducted a thorough comparative analysis of frictional behaviour, examining two distinct workpiece materials, Ti-6Al-4V and 42CrMo4 + QT, in conjunction with a cemented carbide tool coated with TiCN.…”

Section: Frictional Characteristicsmentioning

confidence: 99%

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Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Nassef,

Pape,

Poll

et al. 2024

Lubricants

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Predicting the tribological behaviour in the secondary shear zone in the metal-cutting processes is considered a significant challenge in contemporary research. This work investigated the frictional performance in the secondary shear zone of a planing process using a modified ball-on-disc open tribometer. The values of the coefficient of friction (COF) were tracked between an AISI4140 + QT disc (chip) and a cemented carbide ball (cutting tool) coated with TiAlN under three contact pressures of 0.5, 1, and 2 GPa at a range of sliding speeds starting from 0.2 m/s to 1.6 m/s. The tests were conducted under both dry and lubricated conditions using three commercial cutting fluids of CSF 35 straight oil, Vasco 6000, and Zubora 67H emulsions. Also, the MWFs were tested for their rheological properties and wettability. The tribometer results validated the same COF trend as that in the actual metal-cutting experiments, particularly at 0.5 and 1 GPa in dry conditions. Moreover, Zubora 67H emulsion is proven to be the optimal choice due to it reducing the COF between the rubbing contacts by up to 78%. Furthermore, it showed the lowest contact angle and viscosity index, revealing its ability to easily penetrate, especially at higher temperatures, within the secondary cutting zone.

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Section: Materials and Characterisationmentioning

confidence: 99%

Section: Frictional Characteristicsmentioning

confidence: 99%

Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Nassef,

Pape,

Poll

et al. 2024

Lubricants

View full text Add to dashboard Cite

show abstract

“…MWFs also have a positive effect on reducing the wear of cutting tools. For example, Lakner and Hardt [14] demonstrated for the material Ti-6Al-4V that increased MWF supply pressure significantly reduces tool wear. A large group of MWFs are water-miscible oils that are highly additivated and mixed with water [1,15].…”

Section: Introductionmentioning

confidence: 99%

Tribological Effects of Metalworking Fluids in Cutting Processes

et al. 2023

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An understanding of the proper application of metalworking fluids (MWFs) is necessary for their implementation in efficient production processes. In addition, the knowledge of the process-related aspect of chip transport and the macroscopic cooling effect, the characteristics and properties of lubricant film formation, and the cooling conditions in the secondary shear zone on the chip surface, i.e., in the direct vicinity of the material separation, represent a combined fundamental scientific issue within production engineering. The aim is to transfer methods from the field of tribology of machine elements, which have already led to a considerable gain in knowledge in this discipline, to machining and to couple them with already established approaches to machining. In the case of roller bearings, the contact pressure is in the range as the pressure in the contact zone between the cutting insert and chip. Due to this, established methods might be transferred to the cutting process. In addition to classical pin-on-plate and pin-on-ring friction investigations, film thickness measurements were carried out and compared to machining tests. The coefficient of friction determined in the planing test rig is 0.48 for dry cutting, while it is 0.47 for wet cutting. These two values are much larger than the CoF with MWFs measured on the two tribometers. It is shown that the boundary friction of MWF especially influences the machining process. Thus, additives in MWF might have a high significance in machining.

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“…These results were later validated for different oil types [8] and were also confirmed in [9] with an uncoated pin. Lakner and Hardt used a defined contact between the flank face of a TiCN-coated cemented carbide tool and an AISI4140 shaft to identify the friction coefficient [10]. They determined friction coefficients µ = 0.2-0.3 for dry and wet processes and sliding velocities v s = 40-120 m/min.…”

Section: Introductionmentioning

confidence: 99%

Influence of metal working fluid on chip formation and mechanical loads in orthogonal cutting

Denkena

Krödel

Ellersiek

2021

Int J Adv Manuf Technol

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Metal working fluids are used in machining processes of many hard-to-cut materials to increase tool life and productivity. Thereby, the metal working fluids act on the thermal and on the mechanical loads of the tool. The changing mechanical loads can mostly be attributed to the changing friction between rake face and chip and changes in the chip formation, e.g., the contact length between rake face and chip. However, analyzing those effects is challenging, since a detailed look at the chip formation process is prevented by the metal working fluid. In this paper, a novel planing test rig is presented, which enables high-speed recordings of the machining process and process force measurements while using metal working fluids. Experiments reveal that process forces are reduced with increasing pressure of the metal working fluid. However, the average friction coefficient only changes slightly, which indicates that the reduced process forces are mainly the result of reduced contact lengths between rake face and chip.

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A Novel Experimental Test Bench to Investigate the Effects of Cutting Fluids on the Frictional Conditions in Metal Cutting

Cited by 9 publications

References 38 publications

Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Tribological Effects of Metalworking Fluids in Cutting Processes

Influence of metal working fluid on chip formation and mechanical loads in orthogonal cutting

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