Low initial lubrication procedure in the machining of copper-nickel 70/30 ASTM B122 alloy

Traditional lubrication systems are not environmentally sustainable, being necessary to find techniques less harmful to the environment that provide efficient machining processes to improve cutting conditions. In this paper, it is proposed a new and less polluting lubrication technique called Low Initial Lubrication condition, LIL. It involves applying a low quantity of oil on the workpiece and the rake face of the tool at the beginning of the machining process. This lubrication technique has been tested on cylindrical turning of cupronickel 70/30 alloy, which is widely used in marine and naval applications. Different empirical cutting models are proposed in order to predict cutting forces. Relevant parameters of machining processes, such as the specific cutting energy and shear cutting strength have been evaluated. In addition, FEM simulation with a simple material model is proposed for the prediction of the cutting force. The lubrication system herein researched permits to reduce the value of the cutting force significantly in comparison to dry and flood machining under some cutting conditions.