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Lubricants
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Metalworking Fluids Technology
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Metalworking Fluids Technology

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (31 July 2021) | Viewed by 10109

Special Issue Editors

Dr. Yan Zhou

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Guest Editor
Quaker Houghton, Conshohocken, PA 19428, USA
Interests: metalworking fluids; surface engineering; advanced manufacturing; tribology
Dr. Thorsten Peitsch

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Guest Editor
Carl Bechem GmbH, Hagen, Germany
Interests: metalworking fluids; deformation; chemistry; tribology
Dr. Julius Schoop

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Guest Editor
Department of Mechanical Engineering and Institute for Sustainable Manufacturing, University of Kentucky, Lexington, KY 40506-0108, USA
Interests: metalworking fluids; surface engineering, in-situ characterization; machining; process modeling; surface integrity

Special Issue Information

Dear Colleagues,

The machining and deformation of metals are essential manufacturing processes in modern society, and consequently, the metalworking industry is one of the most critical sectors around the world. Metalworking fluids (MWFs) are integral to this industry, serving to provide cooling, lubrication, cleaning, rust protection, etc. Without MWFs, certain operations would run much less efficiently to the point where machining metals would become impossible. The two basic processes in metalworking are metal deformation and metal removal. There are many aspects in MWFs to consider when assessing a fluid´s suitability for use in a given operation. Such aspects include the metalworking operation, the chemistry of the MWF, workpiece and tool metallurgy, corrosion causes and cures, microbiology, filtration, and environmental impacts. Hence, the development and testing of MWFs for a given machining operation and fluid system can be a complicated task that requires the careful consideration of the various performance and operational elements.

Furthermore, with emerging challenges in metalworking such as high-speed machining, the machining of difficult materials, innovative machining processes (laser cutting and 3D printing), there is a sharp need for improving and expanding the functions of existing MWFs.

This Special Issue aims at the diverse aspects of MWF research and development. Contributions are welcome from both academic researchers and their industrial peers dealing with new MWF chemistries, machining operation impact, and lubrication mechanisms, among others.

Dr. Yan Zhou
Dr. Thorsten Peitsch
Prof. Dr. Julius Schoop
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • metalworking fluid
  • metal removal
  • metal deformation
  • additives
  • materials
  • lubricants
  • metal cutting
  • coolants

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Published Papers (3 papers)

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Research

8 pages, 4748 KiB  
Article
Wear Study of Cubic Boron Nitride (cBN) Cutting Tool for Machining of Compacted Graphite Iron (CGI) with Different Metalworking Fluids
by Long Zhu, Robert Evans, Yan Zhou and Fei Ren
Lubricants 2022, 10(4), 51; https://doi.org/10.3390/lubricants10040051 - 26 Mar 2022
Cited by 4 | Viewed by 2627
Abstract
Due to its desirable mechanical properties, compacted graphite iron (CGI) has been used to replace conventional gray cast iron (CI) in various applications, such as automotive engine blocks and cylinder heads. However, the poor machinability of CGI can lead to excessive tool wear [...] Read more.
Due to its desirable mechanical properties, compacted graphite iron (CGI) has been used to replace conventional gray cast iron (CI) in various applications, such as automotive engine blocks and cylinder heads. However, the poor machinability of CGI can lead to excessive tool wear and consequently high manufacturing costs. Various strategies have been developed to improve the machinability of CGI, including optimizing machining parameters and the development of novel metalworking fluids. In this study, machining of CGI was conducted using cubic boron nitride (cBN) tools under different cutting speeds, with both soluble and full-synthetic water-based metalworking fluids at different levels of sulfur addition and water dilution. The effects of the metalworking fluids on the tool wear behavior were examined. Results showed that at 200 m/min cutting speed, the soluble metalworking fluid at 4% dilution and 0.3% sulfur compound exhibited the best performance, with a cutting distance reaching 23.8 km. In contrast, the least effective soluble metalworking fluid at 9% dilution and 0.3% sulfur compound resulted in a 28.6% decrease in the cutting distance (17.0 km) compared to the best one. At a higher speed (300 m/min), the cutting distance for all metalworking fluids dropped to less than 6.0 km, with the full-synthetic metalworking fluid showing the shortest cutting distance of 4.8 km. Full article
(This article belongs to the Special Issue Metalworking Fluids Technology)
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20 pages, 11412 KiB  
Article
An Evaluation of the Tribological Behavior of Cutting Fluid Additives on Aluminum-Manganese Alloys
by Junhui Ma, Olufisayo A. Gali and Reza A. Riahi
Lubricants 2021, 9(8), 84; https://doi.org/10.3390/lubricants9080084 - 21 Aug 2021
Cited by 6 | Viewed by 2785
Abstract
The introduction of additives enhances the friction and wear reduction properties of cutting fluids (CFs) as well as aids in improving the surface quality of the machined parts. This study examines the tribological behavior of polymer-based and phosphorus-based additives introduced into cutting fluids [...] Read more.
The introduction of additives enhances the friction and wear reduction properties of cutting fluids (CFs) as well as aids in improving the surface quality of the machined parts. This study examines the tribological behavior of polymer-based and phosphorus-based additives introduced into cutting fluids for the machining of Al-Mn alloys. Ball-on-disc tests were used to evaluate the coefficient of friction (COF) and lubrication failure temperature to study the performance of the additives in the cutting fluids. Surface characterization was performed on the sliding tracks induced on the Al-Mn disc surfaces and used to propose the wear and friction reduction mechanisms. The polymer-based additive possessed a higher temperature at which lubrication failure occurred, displayed comparable COF at a lower temperature under certain conditions, and possessed a steadier tribological behavior. However, the phosphorus-based additive was observed to display lower COF and wear damage from 200 °C till failure. The lower COF values for the phosphorus-based additive at 200 °C corresponded with lower surface damage on the Al-Mn surface. The phosphorus-based additive’s performance at 200 °C could be attributed to the forming of a phosphorus-rich boundary layer within the sliding wear track, resulting in less surface damage on the Al-Mn surface and lower material transfer to the counterface steel ball surface. Full article
(This article belongs to the Special Issue Metalworking Fluids Technology)
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15 pages, 16952 KiB  
Article
In-Situ Calibrated Modeling of Residual Stresses Induced in Machining under Various Cooling and Lubricating Environments
by Julius Schoop
Lubricants 2021, 9(3), 28; https://doi.org/10.3390/lubricants9030028 - 3 Mar 2021
Cited by 11 | Viewed by 3228
Abstract
Although many functional characteristics, such as fatigue life and damage resistance depend on residual stresses, there are currently no industrially viable ‘Digital Process Twin’ models (DPTs) capable of efficiently and quickly predicting machining-induced stresses. By leveraging advances in ultra-high-speed in-situ experimental characterization of [...] Read more.
Although many functional characteristics, such as fatigue life and damage resistance depend on residual stresses, there are currently no industrially viable ‘Digital Process Twin’ models (DPTs) capable of efficiently and quickly predicting machining-induced stresses. By leveraging advances in ultra-high-speed in-situ experimental characterization of machining and finishing processes under plane strain (orthogonal/2D) conditions, we have developed a set of physics-based semi-analytical models to predict residual stress evolution in light of the extreme gradients of stress, strain and temperature, which are unique to these thermo-mechanical processes. Initial validation trials of this novel paradigm were carried out in Ti-6Al4V and AISI 4340 alloy steel. A variety dry, cryogenically cooled and oil lubricated conditions were evaluated to determine the model’s ability to capture the tribological changes induced due to lubrication and cooling. The preliminarily calibrated and validated model exhibited an average correlation of better than 20% between the predicted stresses and experimental data, with calculation times of less than a second. Based on such fast-acting DPTs, the authors envision future capabilities in pro-active surface engineering of advanced structural components (e.g., turbine blades). Full article
(This article belongs to the Special Issue Metalworking Fluids Technology)
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