PRESENTED BY:-

UTSAV (36637)
SUDHANSHU NAGARKOTI (36635)
ARUN PRASAD (36652)
KAUSHAL JAISAR (36642)
TUSHAR RAWAT (36636) 1
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Cutting fluids

Cutting fluids may be defined as the

substance either solid, liquid or gas which is
applied at chip tool interface during cutting
operation to facilitate the removal of chips.
Purpose of cutting fluid
To cool the tool.
To cool the workpiece
To lubricate and reduce friction.
To improve surfce finish.
To protect the finished surface from
corrosion.
To cause chip break upto small parts.
To wash away chips.

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Economic Advantages of using
cutting fluids
Reduction of tool costs
Reduce tool wear, tools last longer
Increased speed of production
Reduce heat and friction so higher cutting speeds
Reduction of labour costs
Tools last longer and require less regrinding, less
downtime, reducing cost per part
Reduction of power costs
Friction reduced so less power required by
machining
Desirable properties of cutting
fluids :
High heat absorption capacity.
Good lubrication qualities.
Stability.
Neutral (should not react with work mat. or tool
mat.)
Odourless
Harmless to the skin of operator.
Harmless to the bearings.
Non corrosive to the work.
Tranparency.
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Low viscocity.
Types of cutting fluids

1. Straight cutting oils.

2. Water soluble cutting fluids
3. Synthetic and semi-chemical cutting
fluids.

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Straight or heat oils
These are derived from
petroleum,animal,marine or vegetable
substances and straight or in combination.
Their main function is lubrication and rust
prevention.
They are chemically stable and lower in cost.
They are usually restricted light duty machining

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Water soluble cutting fluids
These fluids form mixtures ranging from
emulsions to solutions.
They are used on 90% of all metal cutting
operations due to their higher specific heat
capacity,higher thermal conductivity.
The water blend is usually in the ratio of 1 part
oil to 20 part water for cutting and 40 part oil to
60 part water for grinding.

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Synthetic and semi-chemical
cutting oils
Synthetic oils refers to any coolant or lubricant
concentrate that doesnt contain petroleum oil.
Semi-chemical oils contain small amount of
minerals plus additives to enhance the
lubricating properties.
They are particularly used in grinding operations
to protect semi-finished or finished ferrous parts
from rusting.

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Solid lubricants
These are also sometimes used in metal cutting
operations..
Some of these are :
Solid lubricant coeff. of friction
1. Talc 0.63
2. Mica 0.48
3. Bentonite 0.45
4. Aluminium stearate 0.40
5. Camphor 0.33
6. Stearic acid 0.19
7. Paraffin wax 0.13
8. Copper stearate 0.12
9. Sodium stearte 0.06
10. Molybdenum disulphide 0.06 11
Pure water
Pure water is the best cutting fluid available
because of :
1. High heat carrying capacity.
2. Cheap and easy available.
3. High fluidity.

The main disadvantage of pure water is that it corrodes

the work material very quickly particularly at high
temperature.
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Methods of application of cutting
fluid to cutting tool

Flood Application
Jet Application
Mist Application

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Flood Application of Fluid:
A flood of cutting fluid is applied on the
workpiece.
Disadvantage :-

Wastage of
cutting fluid.
work piece may
not be clearly
visible during
machining
operation.

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Jet Application of Fluid:

A jet of cutting fluid is applied on the workpiece

directed at the cutting zone.

Disadvantage:-
Power consumption is high as compared to flood application. 15
Mist Application of Fluid:
Cutting fluid is atomised by a jet of air and the
mist is directed at the cutting zone.

Disadvantage:-
Time consuming.

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Requirements of a cutting fluid

1. It should long life ,free of excessive oxide

formation that might clog the circulation system.
2. It should be suitable for a variety of cutting tool
material & cutting operations.
3. It should have good lubricating quality,high
thermal conductivity,low viscosity to permit
easy flow.

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4. It should be transparent when high dimensional
accuracy & fine finish are required.

5. It should present no fire or accidental hazard or

emit harmful odour and dangerous to operator.

6. It should be cheap and easily available.

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Basic actions of cutting fluids
i. Cooling

ii. Friction reduction (Lubrication )

iii. Reduction of the shear strength of the work

material (Rebinder effect).

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Lubrication
Three types of lubrication may exist between the
mating surfaces with relative motion :
i. Fluid film lubrication

ii. Boundary lubrication

iii. Solid friction

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Fluid film lubrication
Occurs when the two surfaces are completely
separated by a fluid film whose thickness is large
as compared to the height of the surface
irregularities . When the surfaces are too smooth
velocity of sliding is high.
Ideal type of lubrication as friction is minimum
and wear is low.

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Boundary lubrication
Occurs when the surfaces are separated by very
thin film composed of a few layers of molecules .
In metal cutting the speed of the parts is so slow,
the pressures are so high & while the cutting
face of the tool is reasonably smooth, the
contacting surface of the chip is so rough that
fluid film lubrication is not possible. Also the
temperature of the lubricant is usually so high
that viscosity at the operating temp. is not
sufficient to provide a load carrying fluid film.
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Solid friction
Occurs when there is actual metal to metal
contact.The absorbed film resists tearing away
under pressure of molecules from metallic,
surfaces in contact.It may fail in local areas, if
there is an adverse combination of high pressure
high velocity of sliding & high temp.

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Reduction in shear strength of
the work material (Rebinder
effect)
In metal cutting large number of fine cracks are
produced on the new work surface. In a
subsequent cut-over the surface, the
compressive stress ahead of the plastic shear
zone tends to rejoin(rebinder effect) these
cracks.However , if a cutting fluid can be
introduced which will prevent this , the stress in
the shear zone may be reduced , thereby
reducing the shear strength of the work material.24
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 Cutting Tools
One of most important components in machining
process
Performance will determine efficiency of operation
Two basic types
Single point and multiple point
Must have rake and clearance angles ground or
formed on them

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 Cutting Tool Properties
Hardness
Cutting tool material must be harder than the
material it is being used to machine i.e. it must have
high hardness to penetrate the work material and cut
it.

Capable of maintaining a red hardness

during machining operation
Red hardness: ability of cutting tool to maintain
sharp cutting edge
Also referred to as hot hardness or hot strength
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 Cutting Tool Properties
Wear Resistance
Able to maintain sharpened edge throughout the
cutting operation.
Same as abrasive resistance.

Shock Resistance
Able to take or absorb the cutting loads and forces
without much change in its properties.

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 Cutting Tool Properties

Shape and Configuration

Must be available for use in different sizes and
shapes so that it can be used effectively.

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 Cutting tool materials

Carbon & medium alloy steels

High speed steels
Cast-cobalt alloys
Carbides
Coated tools
Alumina-based ceramics
Cubic boron nitride
Silicon-nitride-base ceramics
Diamond
Whisker-reinforced materials
Carbon and Medium alloy steels :

Oldest of tool materials.

Used for drills taps,broaches ,reamers.
Inexpensive ,easily shaped and sharpened.
Less hardness and wear resistance.
Limited to low cutting speed operation.

High speed steels (HSS)

High hardness.
Good wear resistance .
Suitable for high positive rake angle tools .
Two basic types of HSS
Molybdenum ( M-series)
Tungsten ( T-series)

M-series - Contains 10% molybdenum, chromium, vanadium

tungsten, cobalt
Higher, abrasion resistance
H.S.S. are majorly made of M-series

T-series - 12 % - 18 % tungsten, chromium, vanadium &

cobalt
undergoes less distortion during heat treating
most commonly used HSS is 1841 which is composed of 18
% tungsten , 4% chromium & 1% vanadium.
 H.S.S.
available in wrought ,cast & sintered (Powder
metallurgy)

Coated for better performance

Subjected to surface treatments such as case-

hardening for improved hardness and wear
resistance or steam treatment at elevated
temperatures

High speed steels account for largest tonnage

 Cast-Cobalt alloys
Commonly known as stellite tools.
Composition ranges 38% - 53 % cobalt
30%- 33% chromium
10%-20%tungsten
Good wear resistance.
Higher hardness.
Less tough than high-speed steels and sensitive to impact forces
Less suitable than high-speed steels for interrupted cutting operations
Continuous roughing cuts relatively high feeds & speeds
Finishing cuts are at lower feed and depth of cut
 Carbides :

Carbides are also known as cemented

or sintered carbides
High elastic modulus , thermal
conductivity.
Low thermal expansion.

2-groups of carbides used for machining

operations
tungsten carbide
titanium carbide
 Tungsten Carbide

Composite material consisting of tungsten-carbide particles

bonded together

Alternate name is cemented carbides

Manufactured with powder metallurgy techniques

Particles 1-5 Mum in size are pressed & sintered to desired

shape

Amount of cobalt present affects properties of carbide tools

As cobalt content increases strength hardness & wear

resistance increases
 Titanium carbide

Titanium carbide has higher wear resistance

than tungsten carbide

Nickel-Molybdenum alloy as matrix Tic

suitable for machining hard materials

Speeds higher than those for tungsten

carbide
Inserts
 Inserts
Individual cutting tool with severed cutting points.

Clamped on tool shanks with locking mechanisms.

Clamping is preferred method for securing an insert.

Carbide Inserts available in various shapes-Square,

Triangle, Diamond and round.

Strength depends on the shape.

Insert Attachment

Fig : Methods of
attaching inserts to
toolholders : (a)
Clamping and (b)
Wing lockpins. (c)
Examples of inserts
attached to
toolholders with
threadless lockpins,
which are secured
with side screws.
 Coated tools :

Unique Properties :
Lower Friction
High resistance to cracks and wear
High Cutting speeds and low time & costs
Longer tool life
Coating materials
Titanium nitride (TiN)
Titanium carbide (Tic)
Titanium Carbonitride (TiCN)
Aluminum oxide (Al2O3)
Cutting tool Characteristics for coating :

High hardness
Chemical stability
Low thermal conductivity
Good bonding
Little or no Porosity

Titanium nitride (TiN) coating :

Low friction coefficients
High hardness
Resistance to high temperatures
Good adhesion to substrate
High life of high speed-steel tools

Titanium carbide (TiC) coating:

Titanium carbide coatings on tungsten-carbide inserts have high flank
wear resistance.
Ceramics :
Low thermal conductivity ,resistance ,high temperature
Resistance to flank wear and crater wear
Ceramics are suitable materials for tools
Aluminium oxide (most commonly used)

Multi Phase Coatings :

First layer Should bond well with substrate
Outer layer Resist wear and have low thermal
conductivity
Intermediate layer Bond well & compatible with both
layers
Coatings of alternating multipurpose layers are also
formed.
Diamond Coated tools :

Use of Polycrystalline diamond as a coating

Difficult to adhere diamond film to substrate
Thin-film diamond coated inserts now
commercially available
Thin films deposited on substrate with PVD & CVD
techniques
Thick films obtained by growing large sheet of
pure diamond
Diamond coated tools particularly effective in
machining non-ferrous and abrasive materials
Alumina-Based ceramics:
Cold-Pressed Into insert shapes under high pressure and
sintered at high temperature

High Abrasion resistance and hot hardness

Chemically stable than high speed steels & carbides

So less tendency to adhere to metals

Good surface finish obtained in cutting cast iron and steels

Negative rake-angle preferred to avoid chipping due to poor

tensile strength
Cubic boron Nitride ( CBN ) :

Made by bonding ( 0.5-1.0 mm ) layer of poly crystalline cubic

boron nitride to a carbide substrate by sintering under pressure
While carbide provides shock resistance CBN layer provides high
resistance and cutting edge strength
Cubic boron nitride tools are made in small sizes without substrate

Fig : (a) Construction of a polycrystalline cubic boron nitride or a diamond layer on a tungsten-carbide insert.
(b) Inserts with polycrystalline cubic boron nitride tips (top row) and solid polycrystalline CBN inserts
(bottom row).
Silicon-Nitride based ceramics (SiN)

They consists various addition of Aluminum Oxide ,ythrium

oxide, titanium carbide

SiN have toughness, hot hardened & good thermal shock

resistance

SiN base material is Silicon

High thermal & shock resistance

Recommended for machining cast iron and nickel based super

alloys at intermediate cutting speeds
Diamond :

Hardest known substance

Low friction, high wear resistance
Ability to maintain sharp cutting edge
Single crystal diamond of various carats used
for special applications
Diamond is brittle
Low rake angle used for cutting edge
 Whisker reinforced & Nanocrystalline
tool materials

New tool materials with enhanced properties:

High fracture toughness

Resistance to thermal shock
High Cutting edge strength
High Hot hardness
Tool life curves for various tool materials
in medium and light turning operations as
a function of cutting speed. Note how the
curve for ceramics crosses over the curve
for TiC as speed , hence temperature,
increases
Effect of cobalt content in TiC tools over
mechanical properties. Hardness is directly
related to compressive strength and hence,
inversely, with wear
Property Carbon HSS Cast Cemente Coated Ceramics Poly - Diamond
and low Cobalt d carbide carbide crystallin
to alloys e
mediu CBN
m alloy
steels

Depth of Light to Light to Light to Light to Light to Light to Light to Very light
cut medium heavy heavy heavy heavy heavy heavy for single
crystal

Finish Rough Rough Rough Good Good Very good Very good excellent
Obtainable
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