Research on difficult‐cut‐material in cutting with application of water vapor as coolant and lubricant

PurposeGreen machining is becoming increasingly more popular due to concern regarding the safety of the environment and human health. The important implementation of stricter Environmental Protection Agency regulations associated with the use of ample amount of coolants and lubricants has led to this study on a new green machining technology with application of water vapor as coolants and lubricants in cutting Ni‐based superalloys and titanium alloy Ti‐6Al‐4V with uncoated carbide inserts (ISO Type K10). The purpose of this paper is to show that machining technology with application of water vapour could be an economical and environmentally compatible lubrication technique for machining difficult‐cut‐materials.Design/methodology/approachIn this paper, the effect of water vapor applications in machining difficult‐cut‐materials have been investigated in detail, the cutting force, the chip deformation coefficient, the rake face wear and the width of tool flank land VB have been examined and analyzed, and a new green cutting technology is researched to machining Ni base superalloys and Ti‐6Al‐4V difficult‐cut‐materials.FindingsThe cutting force of machining Ni base superalloys and Ti‐6Al‐4V was affected by direct water vapor application, being lower than dry cutting and wet machining for all machining conditions; the Λh is the smallest with applications of water vapor as coolants and lubricants compared to dry cutting, pure water and oil water emulsion conditions the tool life extended by about six times than dry cutting, about four times than oil water emulsions at low cutting speed (νc<100 m/min), and about two‐four times than dry cutting, about two‐three time than oil water emulsions at higher cutting speed (νc>100 m/min) during machining Ti‐6Al‐4V with application of water vapor direct into the cutting zone.Originality/valueThe green cutting technology which applies water vapor as coolants and lubricants advocates a new method for machining difficult‐cut‐materials (Ni base superalloys and Ti‐6Al‐4V) without any environment pollution and operator health problem because the cutting force and chip deformation coefficient are reduced, the tool life is extended, and the tool flank wear can be decreased with applications of water vapor as coolants and lubricants to alleviate the adhering and diffusion wear compared to wet cutting and dry cutting.