Troubleshooting lubrication problems
There are a number of issues that can contribute to tool failures and unacceptable surface finishes.
It is not our intent to try to address the myriad possibilities that can affect those variables. However, if machining parameters, tool geometries, feed, speed, depth of cut factors have been addressed, and the problems persist, then there is a good chance that the lubricant that you are using cannot perform to your expectations.
We have focused on emerging technologies to develop formulas that reduce tool wear caused by friction and uneven lubrication.
Sandvik Coromant's website contains an excellent description of common insert wear (photos are the property of Sandvik Coromant)
Built up edge
Wear caused by pressure welding of the chip to the insert. It is most commonly encountered when machining low carbon steel, stainless steel and aluminum. Low speed machining increases the friction coefficient between tool and work piece, causing a build up of heat and increased potential for BUE.
Liquid Solutions machining fluids are designed to provide excellent boundary lubrication, which minimizes BUE.
Insert wear characterized by excessive localized damage on both the rake face and flank of the insert at the depth of cut line. Caused by adhesion (pressure welding of chips) and a deformation hardened surface. A common wear type when machining stainless steels and HRSA.
Liquid Solutions has developed products that minimize notch wear
When the temperature at the cutting edge changes rapidly from hot to cold, multiple cracks may appear perpendicular to the cutting edge. Thermal cracks are related to interrupted cuts, common in milling operations, and are aggravated by the use of coolant.
The use of MQL lubricants greatly reduces the incidence of thermal cracks, especially in milling operations.