Development of Green Cutting by Oil-Water Combined Mist Lubrication

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In this research work, the oil-water combined mist lubrication system that may apply to high-speed turning operations and milling process was developed. This method may replaces using high-pressure and huge flow rate cooing with green machining without oil pollutions. The oil-water combined mist lubrication is consist of two main part, one is very small amount of oil mist that acts as lubricants of cutting point and, second is relatively large amount of water mist that present effective cooling to tool and work materials. The oil mist ejected from nozzle is covered with water mist ejected through co-axial nozzle thus, the oil never spread into circomstaces. Further, the suitable lubricating condition for various cutting speed, cutting depth, work materials and feed rate, by adjusting each flow rates of oil and water. In a 00 year period, milling process of SUS304 stainless steel that is hard to cut material was tested under the complete dry condition and oil-water combined mist lubrication. Compare with these conditions, temperature of work piece decreases by 50 ℃, frank wear width was decreased into a half and a surface roughness was greatly improved by using oil-water combined mist. In a 01 year period, the circular mist supplying system was developed to improve lubrication of end-mill during milling process. This system is consist of both circular chamber and slits that supply mushroom-like shape mist flow which surrounds the tool. Tool failure such as tipping and uneven surface finish was greatly improved by applying the circular mist supplying system.