Microlubrication Effects During End Milling AISI 1018 Steel

Flood cooling is primarily used to cool and lubricate the cutting tool and workpiece interface during a machining process. But the adverse health effects caused by the use of flood coolants are drawing manufacturers' attention to develop methods for controlling occupational exposure to cutting fluids. Microlubrication serves as an alternative to flood cooling by reducing the volume of cutting fluid used in the machining process. In this study the effects of microlubrication during end milling of AISI 1018 steel was investigated using vegetable based cutting fluid aerosol. A solid carbide cutting tool was used with varying cutting speeds and feed rates having a constant depth of cut. A full factorial experiment was conducted and regression models were generated along with parameter optimization for the aerosol mass concentration and the aerosol particle size. The study shows that with a proper selection of the cutting parameters it is possible to reduce the aerosol mass concentration in end milling under microlubrication. But more scientific assessments are needed to lower the mass concentration of the aerosol particles, below the recommended value of 5 mg/m3 by Occupational Safety and Health Administration (OSHA). Limited studies have been reported to investigate the effectiveness and quality of mist produced under microlubrication. No study has been reported to date on end milling 1018 steel under microlubrication.