Dry cutting technology has emerged as a revolutionary approach in modern manufacturing, driven by the need to reduce environmental impact and improve efficiency. With the rapid advancement of high-speed processing technology, the use of cutting fluids has become increasingly common, with flow rates reaching up to 80 to 100 liters per minute. However, this widespread use of cutting fluids has led to significant negative consequences. First, it greatly increases the production cost of parts, as cutting fluid costs account for approximately 16% of the total processing cost, compared to only 4% for cutting tools. Second, it causes severe environmental pollution, such as the discharge of untreated cutting fluids into rivers, lakes, and oceans, which contaminates land, water, and air, affecting ecosystems and human health. Third, it poses direct risks to the health of workers, as many water-based cutting fluids contain harmful chemicals that can cause respiratory issues and skin diseases when inhaled or contacted.
These challenges have prompted the development of dry cutting technology, which aims to minimize or eliminate the use of cutting fluids. Originating in Europe, dry cutting has gained significant traction, especially in Western countries. Germany, for instance, has been at the forefront of this technology, with around 8% of companies adopting it by the mid-1990s, and over 20% by 2003. Japan has also made notable progress, developing dry machining centers that operate without cutting fluids. One such system uses liquid nitrogen cooling to achieve dry cutting smoothly. In China, institutions like the Chengdu Tools Research Institute and Tsinghua University have conducted extensive research on superhard cutting tool materials and coatings, laying a solid foundation for the development of dry cutting technologies.
Understanding the role of cutting fluids is crucial for the successful implementation of dry cutting. These fluids serve three main functions: lubrication, cooling, and chip removal. Lubrication reduces friction between the tool, workpiece, and chip, improving surface quality. Cooling helps dissipate the heat generated during cutting, extending tool life and enhancing machining accuracy. Chip removal ensures efficient evacuation of swarf from the cutting zone, preventing damage to both the tool and the workpiece. Without these functions, dry cutting faces significant challenges, such as increased cutting temperatures, reduced tool life, and poor machining performance.
To overcome these challenges, advanced tool materials and coating technologies are essential. Ceramics, CBN (cubic boron nitride), PCD (polycrystalline diamond), and ultra-fine carbides are commonly used due to their excellent thermal stability and wear resistance. Coated tools, such as TiN, TiC, Al2O3, and MoS2, further enhance performance by reducing friction and heat generation. Additionally, optimizing tool geometry and machine design plays a critical role in ensuring effective chip breaking and removal, especially in high-speed dry cutting applications.
Machine tool design for dry cutting must address heat dissipation and chip management. Proper insulation, cooling systems, and chip evacuation mechanisms are necessary to prevent thermal deformation and maintain machining accuracy. High-speed CNC machines with powerful spindles and feed systems are often required for dry cutting of difficult-to-machine materials like aluminum alloys and composites.
In some cases, pure dry cutting may not be feasible, leading to the adoption of quasi-dry cutting methods such as Minimum Quantity Lubrication (MQL). This technique involves using a small amount of lubricant mixed with compressed air to reduce friction and heat, offering an environmentally friendly alternative to traditional wet machining. MQL significantly reduces fluid consumption while maintaining high-quality results, making it an attractive option for industries seeking sustainable solutions.
Overall, dry cutting represents a major innovation in manufacturing, aligning with global efforts to promote clean and sustainable practices. As tool materials, coatings, and machine designs continue to evolve, the future of dry cutting looks promising, offering a cleaner, more efficient, and environmentally responsible alternative to conventional machining.
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