Impact of cutting fluid velocity and flow rate on wear and surface roughness in turning operations

This study presents the effects of cutting fluid velocity and flow rate on the wear of high-speed steel cutting tools and the surface roughness of machined AISI D2 steel samples. Employing a 2.2 Kw lathe machine, turning operations were performed. A 10 % concentration emulsion or mixture was produced by mixing Blasocut 2000 universal concentrate with water. Tool wear was calculated by measuring the percentage weight loss, whereas, the surface's roughness was measured using a profile meter. To create an emulsion or mixture with a 10 % concentration, Blasocut 2000 universal concentrate was mixed with water. A stopwatch and a measuring beaker were used to measure the cutting fluid's flow rate. Surface roughness could be decreased most successfully with a high flow rate of cutting fluid, whereas wear could be reduced most effectively with a medium flow rate. A deeper cut results in a larger wear surface area on the flanks. For surface roughness, the depth of cut proved to be most effective. which was 1.2 µm at 31 ml/sec cutting fluid flow rate while cutting speed has the most effect on tool wear. While wear could be reduced most effectively at a medium flow rate of Q=43 ml/sec, the surface roughness Ra=0.64 µm could be reduced most effectively at a high cutting fluid flow rate of Q=85 ml/sec. The best surface roughness characteristics were found in the confirmation experiment at a medium cutting speed=100 m/min, a low fluid flow rate of Q=21 ml/sec with a high cutting fluid velocity Vf=100 m/min, a low depth of cut of 0.5 mm, and a high cutting fluid flow rate. Moderate feed rate, medium cutting speed, medium cutting depth, and medium cutting flow rate were determined to be the best cutting parameters