Title: Predicting the effects of cutting fluid on machining force, temperature and residual stress using analytical method

Authors: Xia Ji; Xueping Zhang; Steven Y. Liang

Addresses: School of Mechanical Engineering, Donghua University, Shanghai 201620, China ' School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China ' George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405, USA

Abstract: In the machining process, cutting fluids are used with an objective to control force and temperature thus promoting a longer tool life and better surface finish. However up until this point it has not been well understood how cutting fluid plays a part on the final workpiece residual stress, which is a key performance index in view of its bearing on fatigue life, corrosion resistance, and part geometry variations. This paper presents a quantitative sensitivity analysis of lubrication conditions in terms of cutting force, cutting temperature, and residual stress based on the physics-based method. Results indicate that larger compressive residual stress can be obtained by increasing the flow rate of MQL. However, there is an optimal range of the flow rate to obtain maximal compressive residual stress within the test range. The proposed prediction model can carry a potential to be applied to dry, MQL, and flood cooling machining.

Keywords: residual stress; analytical method; minimum quantity lubrication; MQL flow rate; sensitivity analysis; cutting fluids; machining force; cutting temperature; residual stress; tool life; surface finish; fatigue life; corrosion resistance; part geometry variations; flood cooling machining; dry machining.

DOI: 10.1504/IJCAT.2016.074451

International Journal of Computer Applications in Technology, 2016 Vol.53 No.2, pp.135 - 141

Published online: 31 Jan 2016 *

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