Predicting the effects of cutting fluid on machining force, temperature and residual stress using analytical method

摘要

In the machining process, cutting fluids are used with an objective to control force and temperature thus promoting a longer tool life and better surface finish. However up until this point it has not been well understood how cutting fluid plays a part on the final workpiece residual stress, which is a key performance index in view of its bearing on fatigue life, corrosion resistance, and part geometry variations. This paper presents a quantitative sensitivity analysis of lubrication conditions in terms of cutting force, cutting temperature, and residual stress based on the physics-based method. Results indicate that larger compressive residual stress can be obtained by increasing the flow rate of MQL. However, there is an optimal range of the flow rate to obtain maximal compressive residual stress within the test range. The proposed prediction model can carry a potential to be applied to dry, MQL, and flood cooling machining.