Resource-efficient performance testing of metalworking fluids utilizing single-point milling

ABSTRACT Metalworking fluids have the ability to extend cutting tool life and improve the machinability of materials. There is a need for the development of reliable machining tests which can be used to screen fluids with high confidence to allow for ranking in terms of performance. This study developed a novel methodology utilizing single-point milling to evaluate fluid performance in terms of tool wear and cutting forces across various aerospace alloys. The repeatability of the procedure was assessed and demonstrated by using standard deviation. The study showed alternative cutting fluid compositions could influence tool life performance across all the aerospace material variants. Inconel 718 was shown to be the hardest material to machine followed by Titanium Ti–5Al–5Mo–5V–3Cr and Titanium Ti–6Al–4V. However, with each material, there was a differentiation in fluid performance with up to 11% difference in average tool life between different fluids. GRAPHICAL ABSTRACT