%0 Journal Article
%T Analyzing the Effectiveness of Microlubrication Using a Vegetable Oil-Based Metal Working Fluid during End Milling AISI 1018 Steel
%A Vasim Shaikh
%A Nourredine Boubekri
%A Thomas W. Scharf
%J International Journal of Manufacturing Engineering
%D 2014
%R 10.1155/2014/261349
%X Microlubrication minimizes the exposure of metal working fluids to the machining operators leading to an economical, safer, and healthier workplace environment. In this study, a vegetable oil-based lubricant was used to conduct wear analysis and to analyze the effectiveness of microlubrication during end milling AISI 1018 steel. A solid carbide cutting tool with bright oxide finish was used with varying cutting speed and feed rate having a constant depth of cut. Abrasion was the dominant wear mechanism for all the cutting tools under consideration. Other than abrasion, sliding adhesive wear of the workpiece materials was also observed. The scanning electron microscope investigation of the used cutting tools revealed microfatigue cracks, welded microchips, and unusual built-up edges on the cutting tools flank and rake side. A full factorial experiment was conducted and regression models were generated for both the sides of tool flank wear. The study shows that with a proper selection of the cutting parameters it is possible to obtain higher tool life. 1. Introduction Metal working fluids (MWFs) are used to cool and lubricate the tool/workpiece interface during machining. The MWFs perform several important functions including reducing the friction-heat generation and dissipating generated heat at tool/workpiece interface which results in the reduction of tool wear. MWFs also flush the chips away from the tool and clean the workpiece causing less built-up edge (BUE). Therefore, MWFs cannot be completely avoided; however, their exposure to machine operators is a cause of growing occupational health hazards. U.S. National Institute for Occupational Safety and Health (NIOSH) recommends that occupational permissible exposure limits to MWF aerosols be limited to 0.4£¿mg/m3 of thoracic particulate mass which corresponds to approximately 0.5£¿mg/m3 of total particulate mass as a time-weighted average (TWA) concentration for up to 10 hours per day during a 40-hour workweek [1]. However, the oil mist level in the U.S. automotive parts manufacturing facilities has been estimated to be 20¨C90£¿mg/m3 with the use of conventional lubrication by flood coolant [2]. The exposure to such amounts of metal working fluid may contribute to adverse health effects and safety issues, including toxicity, dermatitis, respiratory disorders, and cancer [3]. Also, the costs related to the use of MWFs range from 7 to 17% of the total costs of the manufactured workpiece [4] as compared to the tool cost which is only about 2¨C4% [5]. Microlubrication is also known as ¡°minimum quantity
%U http://www.hindawi.com/journals/ijme/2014/261349/