An Experimental Approach to Determine the Effectiveness of Minimum Liquid Cooling for End Milling 1040 Steel

Abstract

The end milling process is one of the most common metal removal processes used today its due to versatility in generating machined shapes. However, the intermittent nature of the cutting process together with the variation in the chip thickness occurring during the cutting process makes it difficult to apply cutting fluid without causing thermal shock, particularly to carbide tools. Conventional wisdom [1] states that it is essential to use flood coolant to reduce thermal shock from intermittent cooling, which would otherwise take place. End milling dry is preferred to milling with too little cutting fluid, especially for carbide tool tips. Previous experimental evaluation of minimal quantities of lubrication (MQL) when applied to an end milling operation has proved to be inconclusive as to the effectiveness. This is believed to be due to the intermittent nature of the cutting process and the ineffective heat removal from the cutting zone. In MQL the removal of the generated heat is achieved mainly by convection of the compressed air, and partially by evaporation of the cutting fluid. In this research the effectiveness of the MQL is examined with production machining cutting parameters being used.