APPLICATION OF SUPERABSORBENT COOLANT AS A NOVEL APPROACH TO SEMI-DRY MACHINING

Abstract

Cutting fluids play a significant role in manufacturing processes. Machining certain materials is impossible without them. Due to high temperature and friction during cutting operations, proper cooling and lubrication are necessary to improve the efficiency, quality of the final workpiece and to reduce tool failure costs. This study presents a novel coolant suitable for different machining processes. The focus of this work is the application of a superabsorbent coolant (SAC) during hardened H13 steel machining, Inconel 718 turning, and aluminium silicon alloy tapping and drilling with an uncoated carbide tool. Hence, different machining operations have been attempted to better understand the range of function for SAC. Moreover, the possibility of superabsorbent material use as a coolant has been evaluated in comparison with dry and flood conditions. The use of SAC is a novel method of semi-dry machining that demonstrates the advantages of hydrogels as a coolant and opens a new window for industrial applications. SAC is a superabsorbent polymer enriched by a nanofluid and injected near the cutting zone. Its main purpose, besides improving machining performance, is to safely provide beneficial properties of nanoparticles (higher thermal conductivity and lubricity) and to prevent their distribution in air, which along with other chemical additives, can cause serious occupational and environmental hazards. The results of machining studies indicate that SAC can considerably reduce the friction conditions in the cutting zone, greatly reducing cutting force, while improving surface integrity and enhancing tool life. In addition, the friction conditions at the cutting zone have been improved. Ultimately, chip undersurface roughness was measured to ensure the penetration of the nanoparticles into the cutting region and to reduce friction between the tool and chip. The results show a lower surface roughness of the chip surface.