Investigation of the Effect of the Cutting Fluid’s Flow Rate on Cutting Parameters in Turning AISI 1045

The use of cutting fluids (CF) is regarded as one of the most efficient supplementarymethods to lower production expenses and improve the quality of machined surfaces.In this study, the influence of CF’s flow rate on machining performance of AISI1045 was comparatively investigated in turning operations. The experimental designincluded different cutting velocities, feed rates, cutting depths and three flowing rates(2.5, 4, 6 l/min) of CF. 5% concentration of potassium dichromate (K2Cr2O7) in waterwas used as a CF. The evaluation of machining performance was studied based onthermos-electromotive force (Thermo-EMF), chip shrinkage and formation, and toolwear characterization. The results indicated that high rates of fluid flow into cuttingzone yielded better results in terms of reducing the thermo-EMF, minimizing toolwear and BUE, and improving chip morphology. It was then found that increasing thefluid flow rate during cutting leads to early fracture of the chip and the segmented chipformation. In addition, with an increase in the CF flow rate from 2.5 l/min to 6 l/min,the thermo-EMF generated during turning of AISI 1045 with titanium alloyed carbidetools decreased to 13%, and flange wear to 160%.