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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).

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.

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.

The West European metalworking lubricants market has seen a number of major changes in the past decade.

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.

Outlines the increasing use of unconventional metalworking fluids as one of the measures necessary for manufacturing industries to take to maintain their competitiveness, focusing on Germany. Notes environmental concerns and describes the use of base fluids, additives and the testing compatibility with machine tool elements.

The purpose of this study is to compare the environmental impacts of two additive manufacturing machines to a traditional computer numerical control (CNC) milling machine to determine which method is the most sustainable.

A life-cycle assessment (LCA) was performed, comparing a Haas VF0 CNC mill to two methods of additive manufacturing: a Dimension 1200BST FDM and an Objet Connex 350 “inkjet”/“polyjet”. The LCA’s functional unit was the manufacturing of two specific parts in acrylonitrile butadiene styrene (ABS) plastic or similar polymer, as required by the machines. The scope was cradle to grave, including embodied impacts, transportation, energy used during manufacturing, energy used while idling and in standby, material used in final parts, waste material generated, cutting fluid for CNC, and disposal. Several scenarios were considered, all scored using the ReCiPe Endpoint H and IMPACT 2002+ methodologies.

Results showed that the sustainability of additive manufacturing vs CNC machining depends primarily on the per cent utilization of each machine. Higher utilization both reduces idling energy use and amortizes the embodied impacts of each machine. For both three-dimensional (3D) printers, electricity use is always the dominant impact, but for CNC at maximum utilization, material waste became dominant, and cutting fluid was roughly on par with electricity use. At both high and low utilization, the fused deposition modeling (FDM) machine had the lowest ecological impacts per part. The inkjet machine sometimes performed better and sometimes worse than CNC, depending on idle time/energy and on process parameters.

The study only compared additive manufacturing in plastic, and did not include other additive manufacturing technologies, such as selective laser sintering or stereolithography. It also does not include post-processing that might bring the surface finish of FDM parts up to the quality of inkjet or CNC parts.

Designers and engineers seeking to minimize the environmental impacts of their prototypes should share high-utilization machines, and are advised to use FDM machines over CNC mills or polyjet machines if they provide sufficient quality of surface finish.

This is the first paper quantitatively comparing the environmental impacts of additive manufacturing with traditional machining. It also provides a more comprehensive measurement of environmental impacts than most studies of either milling or additive manufacturing alone – it includes not merely CO₂ emissions or waste but also acidification, eutrophication, human toxicity, ecotoxicity and other impact categories. Designers, engineers and job shop managers may use the results to guide sourcing or purchasing decisions related to rapid prototyping.

The purpose of this paper is to study the tribological behavior and mechanism of water‐soluble bismuth dithiophosphate as the additive of water‐based cutting fluid in aluminum alloy tapping.

Comparable investigation has been made on the lubrication performance of bismuth dithiophosphate and sodium dithiophosphate in aluminum alloy tapping. The aluminum alloy‐machined surface finish was observed on scanning electron microscope. The films on the work‐piece‐machined surface and the tap tool working surface were analyzed by X‐ray photoelectron spectroscopy.

The results indicated that the water medium containing 1 wt% the prepared water‐soluble bismuth dithiophosphate exhibited better tapping efficiency than the liquid paraffin containing 2.5 wt% chlorinated paraffin and 2.5 wt% sulfurized olefin. The bismuth sulfide component in the reaction film on the tap working surface plays a leading role in elevating the tapping efficiency and improving the machined surface finish.

The paper is restricted to the lubrication performance of bismuth dithiophosphate as the water‐based cutting fluid additive in 2024 aluminum alloy tapping.

The test method adopted is very close to the machined method applied in industry. The test results show that the bismuth dithiophosphate can obviously improve the tapping efficiency and the machined surface finish. Thus, it can be applied to the aluminum alloy cutting in automotive and aviation.

An attempt has been made to identify the chemical reaction film sourced from bismuth element and dithiophosphate group on the work‐piece‐machined surface and the tool working surface and their contribution to enhancing the tapping efficiency and improving the machining surface finish. This is helpful to the designers and the practitioners of the additives of metalworking fluid.

SYNOPSIS. A new type of cutting fluid is essential to achieving utilisation of the full potential of Automated Machining (AM). Coolant capabilities frequently determine the scope of multi‐tool machining applications. Identifying operational needs and overcoming AM system constraints has provided a unique opportunity to develop a new synthetic cutting fluid technology. A vision for the future is where the expansion of synthetic lubricant technology will continue to contribute significant benefits to an ever‐widening area of manufacturing industry's lubricant requirements.

A new range of oil additives is to be marketed by Ditton & Reinisch Ltd., 130–132 Cromwell Ed., London, S.W. 7., a company who have, for many years, specialised in the field of surface active agents such as detergents, emulsifying agents etc. This Company are known, internationally, as specialists in the manufacture of complex amides. Their entry into the mineral oil additive field is therefore a logical conclusion.