The performance of cutting fluids when machining aluminium alloys

Abstract

Purpose

The knowledge over the performance of cutting fluids when applied under different machining conditions (such as distinct work material and cutting parameters) is critical in order to improve the efficiency of most machining operations. This paper is concerned with the performance of cutting fluids employed under two distinct machining operations involving aluminium alloys: drilling of AA 1050‐O aluminium applying cutting fluid as a mist and turning of AA 6262‐T6 aluminium alloy using cutting fluids (as a flood) with distinct extreme pressure additives (chlorine, sulphur and phosphor).

Design/methodology/approach

This work reports on a experimental study of the performance of cutting fluids when machining aluminium alloys.

Findings

The results indicated an increase in the flow rate of the mist led to lower feed forces but higher torque, power consumption and specific cutting pressure in the drilling operation (AA 1050‐O aluminium). The surface finish was not drastically affected by the cutting fluid flow rate. When turning AA 6162‐T6 aluminium alloy, in general, best results were observed using 10 per cent fluid concentration applied at the tool‐workpiece interface. The cutting fluid containing chlorine as extreme pressure additive produced lower cutting forces and better surface finish at high cutting speed and low feed rate and depth of cut.

Originality/value

The novel element of this paper is the use of minimal lubrication (drilling) and cutting fluids with distinct extreme pressure (turning).

Citation

Mendes, O.C., Ávila, R.F., Abrão, A.M., Reis, P. and Paulo Davim, J. (2006), "The performance of cutting fluids when machining aluminium alloys", Industrial Lubrication and Tribology, Vol. 58 No. 5, pp. 260-268. https://doi.org/10.1108/00368790610682662