A novel cutting fluid optimizer for sustainable machining with reduced cutting fluid consumption

Abstract

Extravagant consumption of cutting fluid in machining leads to adverse health, environmental, and economic impacts. Traditional flood cooling methods, while crucial for temperature control, friction reduction, and machining accuracy, generate significant waste and environmental contamination. To address these issues, a novel Cutting Fluid Optimizer, patented under Indian Patent Number 505650, has been developed for real-time cutting fluid regulation. The CFO dynamically adjusts coolant flow based on machining parameters, optimizing fluid use while maintaining performance. Experimental trials, to investigate the cutting fluid consumption, cutting forces, surface roughness, and tool life, were conducted on AISI 304 Stainless Steel using Tungsten Carbide inserts, on a conventional lathe. Moreover, the CFO's effectiveness was investigated, under both flooded and MQL conditions with synthetic mineral-based cutting fluids. The CFO achieved substantial reductions in cutting fluid consumption by 27.81% and 22.5% in flooded and MQL conditions, respectively. Furthermore, the CFO improved surface roughness by 10.01% and 7.38% under flooded and MQL conditions, respectively, and significantly reduced cutting forces in both conditions. Tool life was also enriched with the use of CFO in machining zone, by 22% and 6.25% under flooded and MQL conditions respectively. The present study established that the newly developed CFO's adaptive control ensured optimal fluid delivery based on real-time process conditions, reducing thermal stress and preventing localized overheating, thereby promoting sustainable and efficient manufacturing.