It is reported that minimal cutting fluid application can improve cutting performanceĭuring turning ( Varadarajan et al., 2000). Resembles dry machining ( Varadarajan et al., 1998, Of cutting fluid is introduced at high velocity (70 m sec -1) in theįorm of tiny droplets at critical zones so that for all practical purposes it

In this context the best alternative is to introduce pseudo dry milling or Ultra hard cutting tools mayīe introduced but the existing machine tools may not be rigid enough to support It is difficult to implement on the existing shop floor as it needs ultra hardĬutting tools and extremely rigid machine tools. In this context, dry milling is a logical alternative which is totally freeįrom the problems associated with storage and disposal of cutting fluid. Apart from the fact that it gives a foul smell, disposal of cutting fluid is a problem and one has to comply with environmental legislation. Procurement, storage and disposal of cutting fluid incur expenses and large scale use of cutting fluid causes serious environmental and health hazards on the shop floor. International Journal of Manufacturing Systems, 1: 30-45.Ĭonventional surface milling of hardened steel needs application of large quantities of cutting fluid. An Environment Friendly Twin-jet Minimal Fluid Application Scheme for Surface Milling of Hardened AISI4340 Steel. The scheme can be implemented as such on the shop floor with out the need for any major alternations on the existing facilities and it was observed that the new scheme is not only environment friendly but also provided better cutting performance. The new fluid application system offered a reduction in surface roughness (Ra) from 1.177 microns to 0.631 microns, reduction in flank wear from 0.051 to 0.018 mm and reduction in cutting force from 228.25 to 105.79 N when compared to conventional wet milling under the same cutting conditions which requires very large quantity of cutting fluid. Accordingly, an 8 run experiment was designed based on Taguchis techniques. A set of operating parameters for optimum performance was determined using Response Table Methodology. A special minimal fluid applicator was developed which facilitated the independent variation of fluid application parameters such as pressure at the fluid injector, frequency of pulsing, rate of fluid application and mode of fluid application. The present investigation aims at establishing an environment friendly minimal pulsed jet cutting fluid application scheme for surface milling of AISI4340 steel with a hardness of 45 HRC using commercially available carbide tools. The disposal of cutting fluid has to comply with environmental legislation such as OSHA regulations. Surface milling of hardened steel is usually carried out with copious supply of cutting fluid and is obviously associated with problems related to procurement and storage of cutting fluid.

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