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At the present time, green cutting has become the focus of attention in ecological and environmental protection. Water vapor is cheap, pollution‐free and eco‐friendly. Therefore, it is a good and economical coolant and lubricant. To find the discipline of nozzle diameter, the parameters of water vapor jet flow and cooling distance influence on its lubricating action effect, experiments were carried out in which YT15 (P10 type in ISO) tool was used in cutting C45 steel.

The vapor generator and vapor feed system are manufactured. The temperature and velocity distribution of water vapor jet flow influences the velocity such that water vapor fills up the capillaries and forms the boundary lubricating film layer in the cutting zone, and the temperature and velocity distribution of the vapor jet flow section contains the effective area for the lubricating effect. Through the temperature distribution measured, the empirical formula of temperature distribution is obtained and simulated by Matlab. The turning experiment was carried out according to quantity in cutting υ_c=45, 60, 75, 90, 105, 120 mm/min, f=0.1 ∼ 0.3 mm/rev, a_p=1, 2, 3, 3.5 mm and the jet flow parameters were changed, respectively.

It was found that: significant decrease of cutting force can be realized with reduced nozzle diameter, increased the sett pressure and shortened the cooling distance. However, reduced to a certain extent it will lead to the increase of the cutting force. The optimal nozzle diameter is 2 mm for the best lubricating effect. The effect on cutting force of the cooling distance is much better than the setting pressure. Significant decrease of friction coefficient of tool‐chip can be realized with reduced nozzle diameter. However, reduced to a certain extent it will lead to the increase of friction coefficient. Significant thinness of chips can be realized by reducing nozzle diameter. But if the diameter is reduced to a certain degree, chips will be thickened. Increased set pressure and shortened cooling distance can both reduce chip thickness, resulting in reduction of chip deformation coefficient. Since water vapor has the advantage of being cheap, pollution‐free and harmless, and there is no need for disposal and recycling, it is ideal for cooling and lubricating technology in green cutting.

The paper establishes the discipline of nozzle diameter, the parameters of water vapor jet flow and cooling distance influence on its lubricating action effect.

Nowadays, green cutting has become the focus because of its ecological problem and the necessary environment protection, so that the research on experimentation of green cutting with water vapor as coolant and lubricant is studied because water vapor has many benefits of cheapness, no pollution, no harm and no recycling and handling.

The vapor generator and the vapor feed system are manufactured, the distribution of temperature and velocity of vapor jet flow are simulated by MATLAB program, and under the conditions of compress air, oil water emulsion, water vapor as coolant and lubricant and dry cutting, respectively, the turning experimentation of comparison which the tool is YT15, and the working material is steel 45.

Water vapor, as coolant and lubricant, the cutting force is reduced, respectively about 30‐40, 20‐30 and 10‐15 percent by comparing to dry cutting, compressed air and oil water emulsion. The cutting temperature is, respectively about 30, 40 and 50 percent with the other conditions of dry cutting, compressed air and oil water emulsion. The friction coefficient and the chip deformation coefficient are correspondingly decreased and the surface roughness value has been diminished too. Through analysis of the experimental results, water vapor as coolant and lubricant possesses better lubricating action because of the excellent penetration performance and the low lubrication layer shearing strength of water vapor.

Water vapor as coolant and lubricant provides a novel method for realizing no contamination green cutting.

Green machining is becoming increasingly more popular due to concern regarding the safety of the environment and human health. The important implementation of stricter Environmental Protection Agency regulations associated with the use of ample amount of coolants and lubricants has led to this study on a new green machining technology with application of water vapor as coolants and lubricants in cutting Ni‐based superalloys and titanium alloy Ti‐6Al‐4V with uncoated carbide inserts (ISO Type K10). The purpose of this paper is to show that machining technology with application of water vapour could be an economical and environmentally compatible lubrication technique for machining difficult‐cut‐materials.

In this paper, the effect of water vapor applications in machining difficult‐cut‐materials have been investigated in detail, the cutting force, the chip deformation coefficient, the rake face wear and the width of tool flank land VB have been examined and analyzed, and a new green cutting technology is researched to machining Ni base superalloys and Ti‐6Al‐4V difficult‐cut‐materials.

The cutting force of machining Ni base superalloys and Ti‐6Al‐4V was affected by direct water vapor application, being lower than dry cutting and wet machining for all machining conditions; the Λh is the smallest with applications of water vapor as coolants and lubricants compared to dry cutting, pure water and oil water emulsion conditions the tool life extended by about six times than dry cutting, about four times than oil water emulsions at low cutting speed (ν_c<100 m/min), and about two‐four times than dry cutting, about two‐three time than oil water emulsions at higher cutting speed (ν_c>100 m/min) during machining Ti‐6Al‐4V with application of water vapor direct into the cutting zone.

The green cutting technology which applies water vapor as coolants and lubricants advocates a new method for machining difficult‐cut‐materials (Ni base superalloys and Ti‐6Al‐4V) without any environment pollution and operator health problem because the cutting force and chip deformation coefficient are reduced, the tool life is extended, and the tool flank wear can be decreased with applications of water vapor as coolants and lubricants to alleviate the adhering and diffusion wear compared to wet cutting and dry cutting.