Influence of lubrication type and process conditions on milling performance

Industry and research institutions are seeking ways to reduce the use of lubricants for ecological and economical reasons. The most reasonable step should be to reduce the consumption of the cutting fluids. This report presents an investigation into various methods of applying cutting fluids with the objective of deriving optimum lubrication conditions for the milling of steel. To improve the minimum-quantity lubrication technique, the distance between the nozzle and the tool tip was also changed to study the effect on the cutting performance. A series of tests was also implemented under various cutting conditions. Three workpiece materials - P20, S45C, and NAK80 - were machined to evaluate the cutting performance. The machining performance was based on the tool flank wear, cutting force, temperature increase, and surface roughness of the workpiece. Experimental results show that the machining performance is affected by the lubrication type, the distance between nozzle and tool tip, and the workpiece material. Minimum-quantity lubrication with appropriate oil quantity and appropriate distance between the nozzle and tool tip provides the optimum process condition. The machinability of the workpiece also affects the machining behaviour.