Takahiro Ryu

Fundamental Research on Hobbing with Minimal Quantity Lubrication of Cutting Oil Comparison of Cutting Performance with Dry Cutting

Abstract-This paper compares the cutting performance of minimal quantity lubrication (MQL) system with dry cutting in terms of flank wear, crater wear and finished surface roughness when using various kinds of cutting tools. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The results obtained are summarized as follows. (1) When using an uncoated tool, TiNand (Al, Ti) N-coated tools without coating on the rake face, and fully TiNand (Al, Ti) N-coated tools, MQL decreases the flank wear, crater wear and finished surface roughness compared with the wear and the roughness by dry cutting, particularly at the high cutting speed of 159 m/min. The reason suggested is the lubricating properties improved even with an extremely small quantity of cutting oil, which reduces the occurrence of deposited metal on the cutting edge. (2) With both the fully TiNand (Al, Ti) N-coated tools, the MQL system showed better cutting performance in terms of reduced tool wear and reduced finished surface roughness compared with that by dry cutting; in particular, the fully (Al, Ti) N-coated tool is suitable for an MQL system in hobbing.

A study examining the effects of water-miscible cutting fluids for end milling process of carbon fiber reinforced plastic

This study examined the improvements to the tool life and finished surface roughness by using water-miscible cutting fluids in carbon fiber reinforced plastics end milling. In cutting tests, it was found that the use of emulsion type, soluble type, and solution type cutting fluids improved tool life compared with the case of dry cutting. Specifically, significant differences in tool life were observed at a high cutting speed of 171 m/min. In addition, the finished surface exhibited a low level of roughness when the solution type cutting fluid was used, regardless of the cutting speed.This study examined the improvements to the tool life and finished surface roughness by using water-miscible cutting fluids in carbon fiber reinforced plastics end milling. In cutting tests, it was found that the use of emulsion type, soluble type, and solution type cutting fluids improved tool life compared with the case of dry cutting. Specifically, significant differences in tool life were observed at a high cutting speed of 171 m/min. In addition, the finished surface exhibited a low level of roughness when the solution type cutting fluid was used, regardless of the cutting speed.

Influence of water-miscible cutting fluid on tool wear behavior of various coated high-speed steel tools in hobbing

This paper deals with the influence of water-miscible cutting fluid on tool life (flank wear) compared with that with dry cutting and water-insoluble cutting oil in hobbing. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The following results were clarified. (1) The water-miscible cutting fluid used in the test prolongs the tool life for TiN-, TiAlN-, TiSiN- and AlCrSiN-coated tools in comparison with that obtained by dry cutting and water-insoluble cutting oil. (2) It was presumed that the tool wear decreases and the tool life is improved by the lubrication effect of the synthetic lubrication additive, mineral oil and sulfuric EP additive contained in the water-miscible cutting fluid, and also by the cooling effect.