This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Research Advances in Dry and Semi-Dry Machining
Annotation ability available
Sector:
Language:
English
Abstract
The current trend in the automotive industry is to minimize/eliminate cutting fluid use in most machining operations. Research is required prior to achieving dry or semi-dry machining. Issues such as heat generation and transfer, thermal deformation and fluid lubricity related effects on tool life and surface roughness determine the feasibility of dry machining. This paper discusses recent advances in achieving dry/semi-dry machining. As the first step, research has been conducted to investigate the actual role of fluids (if any) in various machining operations. A predictive heat generation model for orthogonal cutting of visco-plastic material was created. A control volume approach allowed development of a thermal model for convective heat transfer during machining. The heat transfer performance of an air jet in dry machining was explored. The influence of machining process variables and cutting fluid presence on chip morphology was investigated through designed experiments. The transport of chips along drill flutes was studied for both wet and dry drilling of Aluminum alloys. Finally a model for cutting fluid mist formation in wet machining is presented. These research findings are being used to gain a complete understanding of the mechanisms at work in dry and semi-dry machining.
Recommended Content
Authors
Citation
Daniel, C., Olson, W., and Sutherland, J., "Research Advances in Dry and Semi-Dry Machining," SAE Technical Paper 970415, 1997, https://doi.org/10.4271/970415.Also In
Design for Environmentally Safe Automotive Products and Processes
Number: SP-1263; Published: 1997-02-24
Number: SP-1263; Published: 1997-02-24
References
- Batzer, S. A. Rao, P. D. Haan, D. M. Olson, W. W. Sutherland, J. W. “An Experimental Investigation of Chip Morphology in Drilling” Proc. of the Second S.M. Wu Symposium on Manufacturing Science May 1996 102 107
- Chao, B. T. Trigger, K. J. “Temperature distribution at Tool-Chip and Tool-Work Interface in Metal Cutting,” Transactions of ASME February 1958 67 81
- Childs, T. H. C. Maekawa, K. Maulik, P. “Effects of Coolant on Temperature Distribution in Metal Machining,” Material Science & Technology 4 November 1988 1006 19
- Churchill, S.W. Ozoe, H. Journal of Heat Transfer 95 78 1973
- Cozzens, D. A. “A Study of Cutting Fluids and Workpiece Surface Error in the Boring of Cast Aluminum Alloys,” Michigan Technological University 1995
- Cselle, T. “New Directions in Drilling,” Manufacturing Engineering August 1995 77 80
- De Chiffre, L. “Functions of Cutting Fluids in Machining,” Journal of the Society of Tribologists and Lubrication Engineers June 1988 514 518
- General Electric Genium Publishing Corporation Heat and Mass Transfer Data Book 16 1985
- Haan, D. M. Olson W. W. Sutherland, J. W. “The Mechanisms of Cutting Fluids in Machining Aluminum Alloys,” Industrial Metalworking Environment: Assessment and Control, Symposium Proceedings Nov. 1995 301 306
- Holman, J. P. Heat transfer McGraw-Hill Book Company New York 1986
- Marano, R. S. Messick R. L. Smolinski J.M. Toth L. “Polymer Additives as Mist Suppressants in Metalworking fluids Part I: Laboratory and Plant Studies-Straight Mineral Oil Fluids,” SAE 95-0245 1995
- Martin, H. “Heat and Mass Transfer between Impinging Gas Jets and Solid Surfaces,” Advances in Heat Transfer 13 1977
- Merchant, M. E. “The Physical Chemistry of Cutting Fluid Action,” American Chemical Society, Division of Petroleum Chemistry 4A 1958 179 189
- Shaw, M. C. Cook, N. H. Smith, P. A. “The Cooling Characteristics of Cutting Fluids,” ASTE Research Report 19 September 1958
- Strenkowski, J. S. Moon, K. “Finite Element Prediction of Chip Geometry and Tool/Workpiece Temperature Distributions in Orthogonal Metal Cutting,” Journal of Engineering for Industry 112 November 1990 313 318
- Yue, Y. Olson W. W. Sutherland, J. W. “Cutting Fluid Mist Formation via an Atomization Mechanism,” Proceedings of the ASME Design for Manufacturability Symposium 1996
- Zheng, Y. Sutherland, J. W. Olson, W. W. “A Predictive Heat Generation Model for Orthogonal Cutting Visco-Plastic Material,” Journal of the Mechanical Behavior of Materials 6 3 1996