Assessment of water-based cutting fluids with green additives in broaching

Abstract

In order to improve the cutting performance in broaching, the lubrication and cleaning effects offered by water-based cutting fluids with green additives need to be studied from the viewpoint of green manufacturing. Therefore, water-based solutions with castor oil, surfactant (linear alkylbenzene sulfonate, LAS), and nanographite were prepared by ultrasonic agitation and sprayed into the zone of broaching via atomization. The performances of the cutting fluids, in terms of the viscosity, specific heat, wetting angle, and droplet size, were evaluated to discuss their effects on the broaching load. Among the fluids, the addition of LAS into oil-in-water (WO-S), where its cutting fluid with 10 wt.% castor oil and 1.5 wt.% surfactant, exhibited the lowest broaching force. With regard to the lubricating and cleaning mechanisms, WO-S has good wettability and permeability, and hence, can lubricate the cutting edge of the tool to decrease the cutting load, cool the cutting edge to keep it sturdy, and clean the surface of the cutting edge to keep it sharp. The results reveal that the simultaneous addition of castor oil and LAS had remarkable effects on the lubrication and cleaning, and resulted in a broaching load reduction of more than 10% compared to commercial cutting fluids. However, the addition of nanographite could not improve the lubrication owing to its agglomeration.

Penetration and lubrication evaluation of vegetable oil with nanographite particles for broaching process

“…As shown in Figs. 7, 8, and 10, wetting angles and their variations, which are representative of the penetration characteristics [1,3,9], are sensitive to the concentration of NGP. The mechanism for this phenomenon is shown in Fig.…”

“…6. However, in the case of pouring, the cutting fluid with a higher viscosity tends to have a better lubrication effect, because it is easier to form a lubricating film without considering the insufficiency of cutting fluid [3,26].…”

“…Cutting fluids are usually indispensable to modern cutting processes, wherein the fluid is responsible for lubrication, cooling, chip removal, and other functions [1][2][3]. In broaching or other cutting applications, the mineral oil-based cutting fluid is largely used because of its acceptable lubrication and cooling effect.…”

Combined lubrication of surface texturing and copper covering for broaching tool

“…Data acquisition instrument (INV3018CT) with sample software (CIONV DASP V10) is applied to make sampling of data with a sampling frequency of 1 kHz. Based on the investigation of Ni et al (2020), the cutting fluid with 10 wt.% castor oil and 1.5 wt.% surfactants, when added with linear alkylbenzene sulfonate, obtains the lowest broaching force and is selected as a cutting fluid for the experiment. An atomization nozzle with a working gas pressure of 7 bar is applied to deliver cutting fluids into the cutting tool.…”

Excellent effect of lubrication performance of chitosan/polyethylene glycol/palygorskite as water‐based lubricating additive on 304 stainless steel and polymer pairs

“…[2][3][4] However, compared with oil-based lubricants, waterbased lubricants had obvious advantages. [5][6][7][8] Some physical and chemical methods cannot completely eliminate the environmental pollution caused by lubricating oil leakage. [9] The water-based lubricant was harmless to the environment and has good environmental compatibility.…”