Skip to main content
SpringerLink
Log in

Role of Eco-friendly Cutting Fluids and Cooling Techniques in Machining

  • Chapter
  • First Online:
Book cover Materials Forming, Machining and Post Processing

Part of the book series: Materials Forming, Machining and Tribology ((MFMT))

Abstract

Nowadays with growing pollution and contamination by hydrocarbon (petroleum) based cutting fluids, the scope for vegetable or synthetic biodegradable esters based eco-friendly cutting fluids is increasing. In this review work, the main focus is on sustainable machining using advanced cutting fluid application techniques with eco-friendly cutting fluids. Understanding the functions and various types of cutting fluids are critically important to maximize its performance during any machining process. Also, cutting fluid application techniques are equally important to minimize the use of cutting fluids for the desired machining processes. This review article focuses on the conventional cutting fluids, function of cutting fluids, ecological aspects of conventional cutting fluids, eco-friendly cutting fluids, cutting fluid application techniques during machining and their performances in order to establish the research field further. An overview of the role of eco-friendly cutting fluids and cooling techniques are discussed and finally concluding remarks and possible scope of future work is presented.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 84.99
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 109.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 109.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. Davim JP (2010) Surface integrity in machining. Springer, London. https://doi.org/10.1007/978-1-84882-874-2

    Book  Google Scholar 

  2. M’Saoubi R, Outeiro JC, Chandrasekaran H, Dillon OW Jr, Jawahir IS (2008) A review of surface integrity in machining and its impact on functional performance and life of machined products. Int J Sustain Manuf 1(1–2):203–236

    Article  Google Scholar 

  3. Bennett EO (1983) Water based cutting fluids and human health. Tribol Int 16(3):133–136

    Article  Google Scholar 

  4. Hasib MA, Al-Faruk A, Ahmed N (2010) Mist application of cutting fluid. Int J Mech Mechatron Eng 10(1):13–18

    Google Scholar 

  5. Bienkowski K (1993) Coolants and lubricants: the truth. Manuf Eng (USA) 110(3):90–92

    Google Scholar 

  6. Sluhan CA (1986) Considerations in the selection of coolants used in flexible machining cells. Society of Manufacturing Engineers. Technical paper pp. 1–5

    Google Scholar 

  7. Spikes H (2004) The history and mechanisms of ZDDP. Tribol Lett 17(3):469–489

    Article  CAS  Google Scholar 

  8. Taylor FW (1906) On the art of cutting metals. American Society of Mechanical Engineers

    Google Scholar 

  9. Wells HM, Southcombe JE (1920) The theory and practice of lubrication: The“ germ” process. Central House

    Google Scholar 

  10. Woodbury RS (1959) History of the grinding machine: a historical study in tools and precision production. Vol. 2, The MIT Press

    Google Scholar 

  11. Brinksmeier E, Meyer D, Huesmann-Cordes AG, Herrmann C (2015) Metalworking fluids—mechanisms and performance. CIRP Ann 64(2):605–628

    Article  Google Scholar 

  12. Debnath S, Reddy MM, Yi QS (2014) Environmental friendly cutting fluids and cooling techniques in machining: a review. J Clean Prod 83:33–47

    Article  CAS  Google Scholar 

  13. Dixit US, Sarma DK, Davim JP (2012) Environmentally friendly machining. Springer Science & Business Media

    Google Scholar 

  14. Sankar MR, Gajrani KK (2017) Cutting fluid emissions and eco-friendly cutting fluid for sustainable machining. In: Proceedings of the national conference on sustainable mechanical engineering: today and beyond (SMETB), Tezpur University, India, pp 157–162

    Google Scholar 

  15. Gajrani KK, Mallick SK, Sankar MR (2017) Comparative studies on mineral oil, eco-friendly bio-cutting fluids treatment and their machining performance. In: Proceedings of the national conference on sustainable mechanical engineering: today and beyond (SMETB), Tezpur University, India, pp 111–116

    Google Scholar 

  16. Gajrani KK, Sankar MR (2017) Past and current status of eco-friendly vegetable oil based metal cutting fluids. Mater Today: Proc 4(2):3786–3795

    Google Scholar 

  17. Tschätsch H, Reichelt A (2009) Cutting fluids (coolants and lubricants). Applied machining technology. Springer, Berlin, Heidelberg, pp 349–352

    Chapter  Google Scholar 

  18. Kuram E, Ozcelik B, Bayramoglu M, Demirbas E, Simsek BT (2013) Optimization of cutting fluids and cutting parameters during end milling by using D-optimal design of experiments. J Clean Prod 42:159–166

    Article  CAS  Google Scholar 

  19. Kuram E, Ozcelik B, Demirbas E (2013) Environmentally friendly machining: vegetable based cutting fluids. In: Green manufacturing processes and systems. Springer, Berlin, Heidelberg, pp 23–47

    Google Scholar 

  20. Lawal SA, Choudhury IA, Nukman Y (2012) Application of vegetable oil-based metalworking fluids in machining ferrous metals—a review. Int J Mach Tools Manuf 52(1):1–12

    Article  Google Scholar 

  21. Nagendramma P, Kaul S (2012) Development of ecofriendly/biodegradable lubricants: an overview. Renew Sustain Energy Rev 16(1):764–774

    Article  CAS  Google Scholar 

  22. Willing A (2001) Lubricants based on renewable resources–an environmentally compatible alternative to mineral oil products. Chemosphere 43(1):89–98

    Article  CAS  Google Scholar 

  23. Fratila D (2009) Evaluation of near-dry machining effects on gear milling process efficiency. J Clean Prod 17(9):839–845

    Article  Google Scholar 

  24. Klocke FAEG, Eisenblätter G (1997) Dry cutting. CIRP Ann 46(2):519–526

    Article  Google Scholar 

  25. Sreejith PS, Ngoi BKA (2000) Dry machining: machining of the future. J Mater Process Technol 101(1–3):287–291

    Article  Google Scholar 

  26. Sharma VS, Singh G, Sørby K (2015) A review on minimum quantity lubrication for machining processes. Mater Manuf Proc 30(8):935–953

    Article  CAS  Google Scholar 

  27. Sharma AK, Tiwari AK, Dixit AR (2016) Effects of minimum quantity lubrication (MQL) in machining processes using conventional and nanofluid based cutting fluids: a comprehensive review. J Clean Prod 127:1–18

    Article  CAS  Google Scholar 

  28. Rao RV (2007) Cutting fluid selection for a given machining application. In: Decision making in the manufacturing environment: using graph theory and fuzzy multiple attribute decision making methods. pp 97–114

    Google Scholar 

  29. Gajrani KK, Sankar MR (2018) Sustainable cutting fluids: thermal, rheological, biodegradation, anti-corrosion, storage stability studies and its machining performance. Encyclopedia of Renewable and Sustainable Materials. https://doi.org/10.1016/b978-0-12-803581-8.11152-x

    Google Scholar 

  30. Liew PJ, Shaaroni A, Sidik NAC, Yan J (2017) An overview of current status of cutting fluids and cooling techniques of turning hard steel. Int J Heat Mass Transf 114:380–394

    Article  Google Scholar 

  31. Singh R, Bajpai V (2013) Coolant and Lubrication in Machining. Handbook of Manufacturing Engineering and Technology 1–34

    Google Scholar 

  32. Palanisamy S, McDonald SD, Dargusch MS (2009) Effects of coolant pressure on chip formation while turning Ti6Al4V alloy. Int J Mach Tools Manuf 49(9):739–743

    Article  Google Scholar 

  33. Smith GT (2008) Cutting tool technology: industrial handbook. Springer Science & Business Media

    Google Scholar 

  34. Soković M, Mijanović K (2001) Ecological aspects of the cutting fluids and its influence on quantifiable parameters of the cutting processes. J Mater Process Technol 109(1–2):181–189

    Article  Google Scholar 

  35. Schey JA (2000) Introduction to manufacturing processes, vol 3. McGraw-Hill, New York etc

    Google Scholar 

  36. Groover MP (2002) Fundamentals of modern manufacturing: materials processes, and systems. John Wiley & Sons

    Google Scholar 

  37. Michalek DJ, Hii WWS, Sun J, Gunter KL, Sutherland JW (2003) Experimental and analytical efforts to characterize cutting fluid mist formation and behavior in machining. Appl Occup Environ Hyg 18(11):842–854

    Article  CAS  Google Scholar 

  38. Shokrani A, Dhokia V, Newman ST (2012) Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids. Int J Mach Tools Manuf 57:83–101

    Article  Google Scholar 

  39. Bhuyan M, Sarmah A, Gajrani KK, Pandey A, Thulkar TG, Sankar MR (2018) State of art on minimum quantity lubrication in grinding process. Mater Today: Proc 5(9):19638–19647

    Google Scholar 

  40. Dhar NR, Kamruzzaman M, Ahmed M (2006) Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel. J Mater Process Technol 172(2):299–304

    Article  Google Scholar 

  41. Dhar NR, Ahmed MT, Islam S (2007) An experimental investigation on effect of minimum quantity lubrication in machining AISI 1040 steel. Int J Mach Tools Manuf 47(5):748–753

    Article  Google Scholar 

  42. Gajrani KK, Ram D, Sankar MR, Dixit US, Suvin PS, Kailas SV (2017) Machining of hardened AISI H-13 steel using minimum quantity eco-friendly cutting fluid. Int J Addit Subtractive Mater Manuf 1(3–4):240–256

    Google Scholar 

  43. Kalpakjian S, Schmid SR (2010) Manufacturing engineering and technology. Prentice Hall, California, United States of America

    Google Scholar 

  44. Foulds L (2012) Cutting fluids. In: Rustemeyer T, Elsner P, John SM, Maibach HI (eds) Kanerva’s occupational dermatology. Springer, Berlin Heidelberg, pp 715–725

    Chapter  Google Scholar 

  45. Vieira JM, Machado AR, Ezugwu EO (2001) Performance of cutting fluids during face milling of steels. J Mater Process Technol 116(2–3):244–251

    Article  CAS  Google Scholar 

  46. Burge H (2006) Machining coolants. The Environmental Reporter, Technical Newsletter, EMLab P&K 4

    Google Scholar 

  47. Shokrani A, Dhokia V, Newman ST (2012) Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids. Int J Mach Tools Manuf 57:83–101

    Article  Google Scholar 

  48. Carlsson AS (2006) Production of wax esters in crambe. Outputs from the EPOBIO Project, CPL Press, Newbury, Berks, p 60

    Google Scholar 

  49. Pettersson A (2007) High-performance base fluids for environmentally adapted lubricants. Tribol Int 40(4):638–645

    Article  CAS  Google Scholar 

  50. Norrby T (2003) Environmentally adapted lubricants–where are the opportunities? Ind lubr Tribol 55(6):268–274

    Article  Google Scholar 

  51. Gajrani KK, Sankar MR, Dixit US (2018) Tribological performance of MoS2-filled microtextured cutting tools during dry sliding test. J Tribol 140(2):021301(1–11)

    Article  CAS  Google Scholar 

  52. Gajrani KK, Reddy RPK, Sankar MR (2018) Tribomechanical, surface morphological comparison of untextured, mechanical micro-textured (MµT) and coated MµT cutting tools during machining. In: Proceedings of the institution of mechanical engineers. Part J, Journal of Engineering Tribology. https://doi.org/10.1177/1350650118764975

    Article  CAS  Google Scholar 

  53. Gajrani KK, Sankar MR, Dixit US (2018) Environmentally friendly machining with MoS2-filled mechanically microtextured cutting tools. J Mech Sci Technol 32(8):3797–3805

    Article  Google Scholar 

  54. Gajrani KK, Reddy RPK, Sankar MR (2016) Experimental comparative study of conventional, micro-textured and coated micro-textured tools during machining of hardened AISI 1040 alloy steel. Int J Mach Mach Mater 18(5–6):522–539

    Google Scholar 

  55. Gajrani KK, Suresh S, Sankar MR (2018) Environmental friendly hard machining performance of uncoated and MoS2 coated mechanical micro-textured tungsten carbide cutting tools. Tribol Int 125:141–155

    Article  CAS  Google Scholar 

  56. Gajrani KK, Sankar MR (2018) Sustainable machining with self-lubricating coated mechanical micro-textured cutting tools. In: Reference module in materials science and materials engineering. Elsevier. https://doi.org/10.1016/b978-0-12-803581-8.11325-6

    Google Scholar 

  57. Gajrani KK, Sankar MR (2017) State of the art on micro to nano textured cutting tools. Mater Today: Proc 4(2):3776–3785

    Google Scholar 

  58. Gajrani KK, Suvin PS, Kailas SV, Sankar MR (2019) Hard machining performance of indigenously developed green cutting fluid using flood cooling and minimum quantity cutting fluid. J Clean Prod 206:108–123

    Article  CAS  Google Scholar 

  59. Gannon JE, Onyekewlu IU, Bennett EO (1981) BOD, COD and TOC studies of petroleum base cutting fluids. Water Air Soil Pollut 16(1):67–71

    Article  Google Scholar 

  60. Gajrani KK, Ram D, Sankar MR (2017) Biodegradation and hard machining performance comparison of eco-friendly cutting fluid and mineral oil using flood cooling and minimum quantity cutting fluid techniques. J Clean Prod 165:1420–1435

    Article  CAS  Google Scholar 

  61. Alves SM, de Oliveira JFG (2008) Vegetable based cutting fluid: an environmental alternative to grinding process. In: LCE 2008: 15th CIRP international conference on life cycle engineering: conference proceedings. CIRP, p 664

    Google Scholar 

  62. Sharma VS, Dogra M, Suri NM (2009) Cooling techniques for improved productivity in turning. Int J Mach Tools Manuf 49(6):435–453

    Article  Google Scholar 

  63. Jayal AD, Balaji AK, Sesek R, Gaul A, Lillquist DR (2007) Machining performance and health effects of cutting fluid application in drilling of A390.0 cast aluminum alloy. J Manuf Process 9(2):137–146

    Article  Google Scholar 

  64. Imran M, Mativenga PT, Gholinia A, Withers PJ (2014) Comparison of tool wear mechanisms and surface integrity for dry and wet micro-drilling of nickel-base superalloys. Int J Mach Tools Manuf 76:49–60

    Article  Google Scholar 

  65. Naves VTG, DaSilva MB, Da Silva FJ (2013) Evaluation of the effect of application of cutting fluid at high pressure on tool wear during turning operation of AISI 316 austenitic stainless steel. Wear 302(1–2):1201–1208

    Article  CAS  Google Scholar 

  66. Babic D, Murray DB, Torrance AA (2005) Mist jet cooling of grinding processes. Int J Mach Tools Manuf 45(10):1171–1177

    Article  Google Scholar 

  67. Dhananchezian M, Kumar MP (2011) Cryogenic turning of the Ti–6Al–4V alloy with modified cutting tool inserts. Cryogenics 51(1):34–40

    Article  CAS  Google Scholar 

  68. Wang ZY, Rajurkar KP, Fan J, Petrescu G (2002) Cryogenic machining of tantalum. J Manuf Process 4(2):122–127

    Article  Google Scholar 

  69. Zhang S, Li JF, Wang YW (2012) Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions. J Clean Prod 32:81–87

    Article  CAS  Google Scholar 

  70. An QL, Fu YC, Xu JH (2011) Experimental study on turning of TC9 titanium alloy with cold water mist jet cooling. Int J Mach Tools Manuf 51(6):549–555

    Article  Google Scholar 

  71. Dhar NR, Islam MW, Islam S, Mithu MAH (2006) The influence of minimum quantity of lubrication (MQL) on cutting temperature, chip and dimensional accuracy in turning AISI-1040 steel. J Mater Process Technol 171(1):93–99

    Article  CAS  Google Scholar 

  72. Emami M, Sadeghi MH, Sarhan AAD, Hasani F (2014) Investigating the minimum quantity lubrication in grinding of Al2O3 engineering ceramic. J Clean Prod 66:632–643

    Article  CAS  Google Scholar 

  73. Itoigawa F, Childs THC, Nakamura T, Belluco W (2006) Effects and mechanisms in minimal quantity lubrication machining of an aluminum alloy. Wear 260(3):339–344

    Article  CAS  Google Scholar 

  74. Gajrani KK, Suvin PS, Sankar MR, Kailas SV (2016) Comparative studies on thermal, rheological behaviour of eco-friendly cutting fluids and their machining performance. In: Proceedings of the 6th international and 27th all india manufacturing technology design and research (AIMTDR) conference. pp 674–678

    Google Scholar 

  75. Kuram E, Ozcelik B, Demirbas E, Sik E (2010) Effects of the cutting fluid types and cutting parameters on surface roughness and thrust force. In: Proceedings of the world congress on engineering, Vol 2, pp 978–988

    Google Scholar 

  76. Paul S, Pal PK (2011) Study of surface quality during high speed machining using eco-friendly cutting fluid. Mach Technol Mater 11:24–28

    Google Scholar 

  77. Gupta K, Laubscher RF (2017) Sustainable machining of titanium alloys: a critical review. In: Proceedings of the institution of mechanical engineers. Part B: Journal of Engineering Manufacture. Vol 231, issue 14, pp 2543–2560

    Article  CAS  Google Scholar 

  78. Khandekar S, Sankar MR, Agnihotri V, Ramkumar J (2012) Nano-cutting fluid for enhancement of metal cutting performance. Mater Manuf Process 27(9):963–967

    Article  CAS  Google Scholar 

  79. Boswell B, Islam MN, Davies IJ, Ginting YR, Ong AK (2017) A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining. Int J Adv Manuf Technol 92(1–4):321–340

    Article  Google Scholar 

  80. Sharma AK, Tiwari AK, Dixit AR (2016) Effects of minimum quantity lubrication (MQL) in machining processes using conventional and nanofluid based cutting fluids: a comprehensive review. J Clean Prod 127:1–18

    Article  CAS  Google Scholar 

  81. Gajrani KK, Suvin PS, Kailas SV, Sankar MR (2019) Thermal, rheological, wettability and hard machining performance of MoS2 and CaF2 based minimum quantity hybrid nano-green cutting fluids. J Mater Process Technol 266:125–139

    Article  CAS  Google Scholar 

  82. Sidik NAC, Samion S, Ghaderian J, Yazid MNAWM (2017) Recent progress on the application of nanofluids in minimum quantity lubrication machining: a review. Int J Heat Mass Transf 108:79–89

    Article  CAS  Google Scholar 

  83. Sharma AK, Tiwari AK, Dixit AR (2015) Progress of nanofluid application in machining: a review. Mater Manuf Process 30(7):813–828

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, Assam, 781039, India

    Kishor Kumar Gajrani

  2. Department of Mechanical Engineering, Indian Institute of Technology Tirupati, Tirupati, 517506, India

    Mamilla Ravi Sankar

Authors
  1. Kishor Kumar Gajrani
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mamilla Ravi Sankar
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Kishor Kumar Gajrani .

Editor information

Editors and Affiliations

  1. Department of Mechanical and Industrial Engineering Technology, University of Johannesburg, Doornfontein, Johannesburg, South Africa

    Kapil Gupta

Rights and permissions

Reprints and permissions

Copyright information

© 2020 Springer Nature Switzerland AG

About this chapter

Check for updates. Verify currency and authenticity via CrossMark

Cite this chapter

Gajrani, K.K., Sankar, M.R. (2020). Role of Eco-friendly Cutting Fluids and Cooling Techniques in Machining. In: Gupta, K. (eds) Materials Forming, Machining and Post Processing. Materials Forming, Machining and Tribology. Springer, Cham. https://doi.org/10.1007/978-3-030-18854-2_7

Download citation

  • DOI: https://doi.org/10.1007/978-3-030-18854-2_7

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-030-18853-5

  • Online ISBN: 978-3-030-18854-2

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation