Effects of Cutting Fluid on Machining High Silicon Aluminum Alloys

Abstract

The following oils and emulsions were used in machining high silicon aluminum alloys containing 18.819.8% Si with a carbide tool having the tip of P30 or K10.
The oils used were the sulfurized fatty oil-mineral oil blend, the chlorinated fatty oil-mineral oil blend, and their mixture.
The emulsions were composed of one part emulsifiable oils, which were made of each blend mentioned above and non ionic surface agent, and 19 part water.
The fluid was supplied, through a jet nozzle, from the bottom up along the tool flank at the rate of approximately 450 cc/min.
The cutting conditions were chosen as follows : cutting speed, 60200 m/min ; depth of cut, 1.5 mm ; feed, 0.075 mm/rev.
The flank wear with time and the roughness of finished surface were measured and the finished surface was observed microscopically by means of replica. The mechanism of the action of cutting fluids for high silicon aluminum alloys was discussed from the above results.
The main results are as follows.
Generally, the action of cutting fluid in machining those aluminum alloys with a carbide tool is about the same as in cutting steels.
The fluids containing sulfurized oil (not mixed with water) and emulsion containing chlo rinated oil show the critical point in the flank wear curve at the relatively early steag of cutting.
The fluids added with water give rather poor surface finish than active oils.