natural lubricants machining

1. Study on lubricating characteristic and tool wear with
water vapor as coolant and lubricant in green cutting
Vipul Sharma
Roll no. 19MF06004
Manufacturing Engineering
School of mechanical sciences
IIT BBS
Seminar guide
Dr . G .Baratarya

2. CONTENTS
1. GREEN
MANUFACTURING
THE PHILOSPHY
2. GREEN CUTTING
3. THE CONCEPT OF
LUBRICATION
PENETRATION
4. EXPERIMENT SETUP
AND PARAMETERS
5. RESULT AND
DISCUSSION
6. CONCLUSION
7. REFERENCES

3. GREEN MANUFACTURING
What:
 It is a method for manufacturing that minimizes waste and
pollution achieved through product and process design.
 Concern the safety of environment and operator
health
WHY:
 Eliminates waste
 Great reputation of firm in public
 Saves useless cost

4. Green cutting
 Use of water vapor (WV), gases (O2 & CO2), WV+CO2 ,
WV+ O2 as coolant and lubricant to improve frictional and
thermal condition at tool chip interface.
 conventional cutting fluids easily cause environment and
health problems and also add up 16- 20 % of machining
costs for recycling and waste disposal.
 Cheap ,pollution free cutting , safe , non toxic and no
problem of recycle and waste disposal.
 It reduce main cutting force and reduces lower cutting
temperature and chip deformation coefficient than others
lubricating conditions.

5. Advantages
 Carbon dioxide(CO2) gas as coolants and lubricants
reduced the cutting force and obtained a higher tool life.
 Oxygen gas (O2) was an effective agent to reduce contact
length of tool–chip, reduce the cutting force but shorter
tool life.
 Water vapor(WV) lubrication ensures more uniform
cooling ,increase the carbide cutting tools lifetime also.
V.A. Godlevski, et al.,Water steam lubrication during machining, Tribologia 162 (6) (1998) 11.
V.V. Podgorkov, et al., Patent of USSR #1549721 MCI B23Q, Method of cutting in application, 1992 (in Russia).

6. Concept of lubrication penetration
• cutting fluids access
into the cutting zone
by the kinetic action of
capillary network
existing in tool–chip
interface.
• capillaries formed by
abrasive and groove
action between tool
rake face and chip
bottom.
• penetration time
should be less than
capillary lifetime, so
there is a storing
time for better the
penetration
performance .
J.A. Williams, The action of lubricants in metal machining, J. Mech. Eng.
Sci. 19 (1977) 202–212.

7. Experiment setup
 Tool: cement carbide P10
 Operation : Turning
 The ANSI 1045 steel as work material.
 Lathe.
 Vapor steam generator, vapor feeding system .
 Cutting force is measured by dynamometer .
 Width of tool flank wear by CCD on-line measuring system.
 Cutting temperature by thermocouple.

8. Aim and Parameters
 Aim of study is to investigate the lubricating effect of water vapor, carbon
dioxide gas, oxygen gas and mixture of vapor and gas (WV&C and WV&O)
applied directly to the cutting zone in machining.
 The turning experiments have cutting υc = 117.6 mm/min, f = 0.1 mm/rev and
depth of cut (ap)= 1–3 mm, as lubrication conditions listed below
Study on lubricating characteristic and tool wear with water vapor as coolant and lubricant in green cutting Junyan Liu a, Rongdi Han a, Li Zhang a, Hongbin Guo b.

9. (a) Vapor feeding
system
(b) Charge Coupled
Device
(CCD)mechanism
(c)System skeleton (d)Vapor feeding system
(e)The direction of water vapor jet
flow
J.Y. Liu, Han R.D., Y.F. Sun, Research on experiments and action mechanism with water vapor as coolant and lubricant in green cutting, Int. J. Machine Tools Manuf. 45 (2005) 687–
694.

10. Results and discussion
Cutting force:
• Main cutting force Fc increases with growth of the
depth of cut
• WV&C reduces much lower with lager depth of cut
than other applications.
• (WV&C) has high speed jet flow by nozzle, and they
will fill up the capillaries of tool–chip interface
• High temperature form boundary lubricating layer
with higher adsorption strength and lead to reduce
friction of tool–chip contact zone and the Fc.
Temperature
• increased little with the depth of cut increasing.
• water vapor, gases and mixture of vapor and gas
reduce the θ much lower than dry cutting.
• Decrease contact friction and cooling effect by
heat convection (high heat capacity).
V.A. Godlevski, et al.,Water steam lubrication during machining, Tribologia 162 (6) (1998) 11.

11. The chip deformation coefficient Λh
• the value(Λh = hch/hD) is smaller, the
chip thickness will be thinner and
the lubrication status will be better in
tool–chip interface.
• The chip deformation Λh is the
smallest with water vapor as coolant
and lubricant
• the chip coil is increased and the
length of tool–chip is reduced and
impoved friction condition.

12. Width of tool flank wear land VBmax
• For this turning experiments were
carried out with f = 0.1 mm/rev, ap = 1.0
mm and Vc = 60–117.6 mm/min
• tool flank wear land VBmax is measured
by CCD measuring system.
• at higher cutting speed (υc = 117.6 m/min),
carbon dioxide (CO2) gas can effectively reduce
the maximum width of tool flank wear land
• carbide tool-life in 4–5 times in turning at higher
cutting speed.
• oxygen gas (O2) reduces the VBmax value to
minimum at moderate cutting speed (υc = 84
m/min)
• WV&C or WV&O can reduce the VBmax value to
minimum at lower cutting speed (υc ≤ 67.2
m/min).

14. J.Y. Liu, Han R.D., Y.F. Sun, Research on experiments and action mechanism with water vapor as coolant and lubricant in green cutting, Int. J. Machine Tools Manuf. 45 (2005) 687–694.

15. Conclusion
(1) The cutting force is reduced less about 20–40%
(2) The cutting temperature is decreased
(3) The tool life is extended much longer in direct on
applications of water vapor, and mixture of vapor and
gas than dry cutting,
(4) The tool wear can be reduced with application of
carbon dioxide gas or water vapor in machining carbon
steel.
(5) Water vapor and mixture of vapor and gas are as
coolants and lubricants have better benefits as they are
cheapness and pollution-free and no harmful.

16. References
X.B. Wang, Green machining in metal cutting, Chin. J. Mech. Eng. 36 (8) (2000) 6–10.
V.V. Podgorkov, et al., Patent of USSR #1549721 MCI B23Q, Method of cutting in application, 1992 (in
Russia).
V.A. Godlevski, et al., Water steam lubrication during machining, Tribologia 162 (6) (1998) 11.
J.Y. Liu, Han R.D., Y.F. Sun, Research on experiments and action mechanism with water vapor as
coolant and lubricant in green cutting, Int. J. Machine Tools Manuf. 45 (2005) 687–694. [16] R.D. Han,
J.Y. Liu, The kinetic modelling of cutting fluid penetrated capillary during machining, Lubr. Eng. (1)
(2005 Jan.) 31–33, serial No. 167.
Study on lubricating characteristic and tool wear with water vapor as coolant and lubricant in green
cutting Junyan Liu a,∗, Rongdi Han a, Li Zhang a, Hongbin Guo b

17. Thank you