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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).

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

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.

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

This study aims to determine the properties of a new non-toxic cutting fluid and compared with cutting fluid based on mineral oil.

The tool wear was measured under dry and wet cutting conditions. The non-toxic cutting fluid was compared with cutting fluid based on mineral oil. The experiments were carried out using CTX 310 ECO numerical control lathe. The wear of the cutting tools was measured by means of stereo zoom microscopy (SX80), while the elements were identified through scanning electron microscopy (JSM 7100F). The workpiece surface texture was studied using a Talysurf CCI Lite non-contact 3D profiler. The contact wetting angle was established with a KSV CAM 100 tester.

The non-toxic cutting fluid has reached comparable coefficient of friction with a coolant containing mineral oil. The use of the non-toxic cutting fluid with low foaming tendency resulted in lower wear.

Machining processes require that cutting fluids be applied to reduce the tool wear and improve the quality of the workpiece surface. Cutting fluids serve numerous purposes such as they act as coolants and lubricants, remove chips and temporarily prevent corrosion of the product.

The investigations discussed in this paper have contributed to the development of non-toxic and environmentally friendly manufacturing because of the use of cutting fluid containing zinc aspartate and its comparison with commonly used cutting fluid.

No one particular fluid has cooling and lubrication properties suitable for every metalworking application. The purpose of this paper is first, to investigate the effect of anionic and nonionic mixed emulsifier system in stabilization of cutting fluid formulations and second, to study the interaction synergism of the fulfill additives of metalworking fluids to achieve low scar diameters, high stability, anti rusting and corrosion properties.

A lot of set mixtures in this work were formulated to get the demand needed for soluble oil metalworking fluids. It was based on a blend of emulsifier package (anionic‐non ionic), and in order to reach acceptable manufacturing conditions, coupling agent, stabilizer, biocide, base oil and anti‐rust additives were added to the formulation. Different percentages of these components were incorporated to optimize the stability of the emulsifier system. Standard tests were carried out to evaluate the performance of oil‐in‐water (O/W) emulsions as lubricating and cooling fluids in machining operations. The evaluation was drawn in five factors; oil stability, emulsion stability, pH, anti‐rust (corrosion inhibition), biological activity and extreme pressure performance tests.

All tests achieved excellent results according to the ASTM. From the obtained results, the formula (named EPRI 950) exhibited a good performance compared with the commercial cutting fluid.

This work investigates the effect of anionic and nonionic mixed emulsifier system in stabilization of cutting fluid formulations; and the interaction synergism of the fulfill additives of metalworking fluids to achieve low scar diameters, high stability, anti‐rusting and corrosion properties.

As more stringent environmental legislation is enforced throughout Europe manufacturing businesses, employing metal cutting processes, can no longer ignore the growing importance of environmental aspects relating to cutting fluids. Businesses, through market forces, are being forced into offering a “clean solution” to the metal cutting processes which they operate. Cutting fluids despite playing an important role in metal cutting, have considerable environmental impact. There is a need therefore to understand the role of cutting fluids within the cutting process in order to evaluate possible environmentally friendly alternatives to the use of cutting fluids. In order to achieve this the operating environment in which the process is being carried out, and the consequences of removing the cutting fluid from the process altogether has to be assessed. This paper therefore, reflects on the role of cutting fluid and the implications of their use. Viable methods of reducing cutting fluid consumption are also reported, together with efficient methods of cutting fluid utilisation (e.g. minimum quantity delivery systems). Finally, the difficulties experienced in removing cutting fluids from the metal cutting process are highlighted through the consideration of dry cutting technologies.

This paper aims to formulate a new metal working fluid (MWF) composition including some eco-friendly emulsifiers, corrosion inhibitor, biocide, and non- edible vegetable oil (castor oil) as the base oil. To achieve this aim, five MWFs with different hydrophilic–lipophilic balance (HLB) value as 10, 9.5, 9, 8.5 and 8 were prepared to identify the optimum HLB value that gives a highly stable oil-in-water emulsion. The performance of castor oil based MWF was evaluated using tool chip tribometer and drill dynamometer. The surface morphology of steel disc and friction pin was performed using scanning electron microscope (SEM) and 3D profilometer. The results revealed that the use of the prepared cutting fluid (E1) caused the cutting force to decrease from 500 N for dry high-speed steel sample to 280N, while the same value for a commercial cutting fluid (COM) was recorded as 340 N at drilling speed and cutting feed force as 1120 rpm and 4 mm/min., respectively.

A castor oil-based metalworking fluid was prepared using nonionic surfactants. The composition of the metalworking fluid was further optimized by adding performance-enhancing additives. The performance of castor oil based MWF was analyzed using Tool chip tribometer and Drill dynamometer. The surface morphology of steel ball and a disc was done using 3D profilometer and SEM.

Studies revealed that castor oil-based MWF having Monoethanolamine (MEA) as corrosion inhibitor was found to be highly stable. The drilling dynamometer and tool chip tribometer studies showed that castor oil-based MWF performance was comparable to that of commercial MWF.

This study aims to explore the performance of the castor oil based metalworking fluid (MWF) using tool chip tribometer and drill dynamometer.

The conventional MWFs are petroleum derives and are unsustainable. Use of non-edible plant-based oils for preparing the MWF will not only be conserved environment but also add value addition to agricultural crops.

The social Implications is aiming to decrease the environmental impact that results from the using of mineral cutting fluids.

The originality of this work is to replace the mineral oil and synthetic oil based cutting fluids with more eco-friendly alternatives one. In addition, the investigation will focus on developing functional additives required for cutting fluids which are environmentally benign.

This article shows how a rational approach to the selection of cutting fluids can be made from an appreciation of the principle factors and mechanisms involved. Attention is also drawn to the benefits of using the same grade of oil for machine lubricant and cutting fluid where this is practicable.

This article aims to collect data on the aluminum alloy 7050-T7451 machinability used in the manufacturing of aeronautical structures, using the combination of the jatropha vegetable-base soluble cutting oil in relation to the canola vegetal and semisynthetic mineral oils and the technique to apply cutting fluid by flood in relation to the Minimum Quantity Lubrication (MQL) in the milling process (HSM – high-speed machining).

It was observed that the jatropha vegetal cutting oil presented the best results in relation to requirements for lubrication, superficial mean roughness (index Ra) and shape errors in relation to the other oils in both the techniques to apply fluid which were tested. Comparing the application techniques, the jatropha vegetal oil offered an increase in the life span of the cutting tool, using the flood technique, exceeding in almost six times the machined length of the cutting tool in relation to the MQL technique in the same process conditions.

The Jatropha vegetable-base cutting oil, besides being produced from a renewable source, has inherent characteristics that can help attain a sustainable manufacturing, mainly with the use of the flood technique to apply cutting fluid in the aluminum alloy 7050-T7451 machining.

The Jatropha (vegetable) oil, in relation to its physicochemical properties, appeared to be the best one fit for being used in the machining of aluminum alloys 7050-T7451 because it did not interfere with any of the elements involved in the formation of intergranular corrosion and/or pitting, which are not allowed in the aeronautical production of parts. Jatropha (vegetable) cutting oil, besides being produced from a clean and renewable source, has the inherent characteristics that can help attain a sustainable manufacturing.

Many machining researches are focused on cutting tools mainly due to the wear developed as a result of high temperatures generated that accelerate thermally related wear mechanisms, consequently reducing tool life. Cutting fluids are used in machining operations to minimize cutting temperature although there is no available indicator of their cooling ability. In this study, a method to determine the cooling ability of cutting fluids is proposed. A thermocouple technique was used to verify the chip‐tool interface temperature of various cutting fluids during turning operation. The method consists of measuring the temperature drop from 300°C up to room temperature after heating a standardised AISI 8640 workpiece and fixing it to the chuck of a lathe and with a constant spindle speed of 150 rpm the cutting fluid was applied to a specific point. The temperature was measured and registered by an infrared thermosensor with the aid of an AC/DC data acquisition board and a PC. The convective heat exchange coefficient, h, was determined and used to classify the cooling ability of the cutting fluids. The machining tests showed that the application of the fluid with better cooling ability will not always guarantee lower chip‐tool interface temperature.

WHEN METALS ARE SHEARED or “cut” a compressive force of high intensity is applied to the metal by the cutting tool. The metal crystals are subjected to this force and the resulting stresses cause certain crystals to slip or flow in various directions along planes of slippage, the direction of slip normally being along planes of greatest atom density.

NEW INDUSTRIAL MATERIALS, the demand for higher productivity and the requirements for ever smaller tolerances have resulted in great advances in machine tool design and in cutting tool materials. Cutting fluids have a significant part to play in this story but they can only play their full part if they are correctly chosen and if their proper functions are understood. Increased rates of metal removal can then be achieved and problems associated with difficult or hazardous machining operations reduced or even eliminated.