Ecological aspects of the cutting fluids and its influence on quantifiable parameters of the cutting processes

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Abstract

This contribution gives an analysis of the ecological parameters of the cutting fluids and its influence on the machinability parameters. Evaluation of quality parameters of the cutting fluids is based on output parameters of production process considering also ecological norms. Some results of machinability tests, which were done in tapping threads into standard reference steel C 45 E4 and Al-alloy AlMgSiPbBi for free cutting show how it is possible to achieve acceptable machinability parameters by use of new environment-friendly cutting fluid. The cutting parameters were chosen from the technological database with respect to particular machined material/cutting tool combinations. This approach has been used to quantify the performance of the existing products, compare products in the marketplace, and search for novel cutting aid additives.

Introduction

Cutting fluids have been introduced into the cutting process with the purpose to improve the characteristics of the tribological processes which are always present on the contact surfaces between the tool and the workpiece. The use of cutting fluids increases the tool life, contributes to a more economical cutting speed and generally improves the efficiency of the production systems when taken as a whole.

Due to the multiplicity of negative effects the cutting fluid wastes produce on mankind and our environment, in modern production there has been an increasing attention to carefully select efficient cutting fluids that would in addition to being efficient be also environment-friendly.

Besides the usual tribological requirements, new cutting fluids have to satisfy the requirements of environment protection set either by in-house regulations, or regulations imposed by the state or international ISO 14000 standards. In most cases ecological parameters of the cutting fluids are setting new constraints on machinability parameters. Therefore, manufacturers as well as end users should find it in their common interest to develop new kinds of cutting fluids whose quality will be identifiable in terms of machinability parameters as well as ecological parameters.

By the development of new cutting fluids with quantifiable performance characteristics it is very useful to use the tapping test [1]. Tapping is a multipoint metal cutting operation and is considered to be one of the most difficult operations in metal removal. The efficiency of the tapping operation can be quantified by the amount of torque required to cut the thread [2].

The pioneer work using tapping and statistical approach as a method for evaluating the performance of cutting oils was conducted by Flemming and Sudholz [3].

Section snippets

Environmental problems occurring within the manufacturing process

Since the beginning of this century manufacturing processes have been systematically and scientifically developed and analysed. In many cases it has been attempted to achieve a maximum efficiency in association with economic manufacturing conditions. The task to manufacture a product by adding process materials and energy to raw materials, inevitably runs into conflict with arguments about the resultant emissions and waste. In search of solutions and ways to improve machining processes it is

Background

We are looking for cutting fluids which would better meet the ecological demands. For this reason new semi-synthetic fluid Teolin AIK (Table 1) was developed in order to replace current cutting oil with chlorinated hydrocarbons Kuteol CSN 5. This new cutting fluid is a mixture of alkiestres of phosphorus acid with condensation products of high grease acid and has following characteristics:

  • good solubility with water in all proportions;

  • clinical investigations of Teolin AIK influences on human

Conclusion and prospects

Cutting fluids are among the most commonly used process materials in the metal working industry. They help to achieve a prescribed result in terms of tool life, surface finish and accuracy-to-size, and make chip-breaking and chip-transport easier. Nevertheless, they do give rise to certain problems in the immediate working environment and in waste disposal. Due to the increasing number of laws and directives governing industrial safety and environmental protection, the use of cutting fluids is

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