Title: Reproducibility of a reaming test

Authors: L. Pilný; P. Müller; L. De Chiffre

Addresses: Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet, Building 427S, DK-2800 Kgs. Lyngby, Denmark ' Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet, Building 425, DK-2800 Kgs. Lyngby, Denmark ' Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet, Building 425, DK-2800 Kgs. Lyngby, Denmark

Abstract: The reproducibility of a reaming test was analysed to document its applicability as a performance test for cutting fluids. Reaming tests were carried out on a drilling machine using HSS reamers. Workpiece material was an austenitic stainless steel, machined using 4.75 m•min−1 cutting speed and 0.3 mm•rev−1 feed. A mineral straight oil and a water-based lubricant at two different oil concentrations were compared with respect to hole quality, evaluated in terms of surface finish (conventional arithmetic mean roughness Ra and roughness profiles), and hole geometry (hole diameter and roundness). Process reproducibility was assessed as the ability of different operators to ensure a consistent rating of individual lubricants. Absolute average values as well as experimental standard deviations of the evaluation parameters were calculated, and uncertainty budgeting was performed. Results document a built-up edge occurrence hindering a robust evaluation of cutting fluid performance, if the data evaluation is based on surface finish only. Measurements of hole geometry provide documentation to recognise systematic error distorting the performance test. [Received 14 May 2013; Revised 30 September 2013; Accepted 13 October 2013]

Keywords: cutting fluid performance; cutting fluids; reaming test; process reproducibility; test uncertainty; surface finish; hole geometry; built-up edge; BUE; austenitic stainless steel; lubrication; hole quality; surface finish; surface roughness; hole geometry; hole diameter; hole roundness.

DOI: 10.1504/IJMR.2014.062441

International Journal of Manufacturing Research, 2014 Vol.9 No.2, pp.157 - 172

Published online: 29 Jul 2014 *

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