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Materials Today: Proceedings 18 (2019) 5019–5031 www.materialstoday.com/proceedings

ICMPC-2019

A Review On Cooling Systems Used In Machining Processes

Soham Deshpandea*, Yogesh Deshpandeb
a-b
Department of Industrial Engineering, Shri Ramdeobaba College of Engineering and Management, Nagpur

Abstract

Employing a cooling system is a difficult task, in a metal cutting operation, which can gain maximum productivity. However,
machining pose many challenges in terms of rapid tool wear due to high temperature generated at cutting zone. Many trials are
being done to overcome these challenges by using some techniques of cooling. The present work describes a review of the
cooling systems based on their characteristics in machining process. The study focuses on effects of cutting temperature and tool
life in various cooling, which significantly associated in metal cutting. The study reviewed some cooling systems such as dry
cutting, conventional cooling, cryogenic cooling, minimum quantity lubrication, nano fluid and air cooling. The cooling sequence
used in this paper also provides importance of the use of cooling in metal cutting. This flow also makes these operations very
economical. The study reveals use of minimum amount of fluid in machining and makes it more sustainable. The various cooling
strategies discussed here, are helpful to decide the optimal way in improving the performance of machining, in terms of tool life
by controlling temperature at cutting zone.
© 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019

Keywords: Machining process, dry cutting, conventional cooling, cryogenic techniques, minimum quantity lubrication, nano fluid, air cooling,
cutting temperature, tool life.

1. Introduction

In metal cutting operations, extreme heat is generated at cutting region result in excessive tool wear which
directly affects on productivity of the process. In dry machining the metal chip remains in close proximity to the
tool-work piece interface leading to excessive heat generation that causes chip damage affects on tool performance
results in low productivity. Therefore, to remove heat from cutting region air cooling, fluid based cooling, liquid
phase cooling, etc. are preferred in machining. Moreover, the presence of appropriate cooling system enhances
machining performance.
*
Corresponding author Tel:+918208311196
E-mail address: deshpandesr@rknec.edu

2214-7853 © 2019 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
5020 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031

The effect of cooling and lubrication depends on fluid flow parameters, fluid characteristics and technique of
fluid delivery to cutting region. So, choosing a correct cooling system is very difficult task. The importance of
various cooling systems with aim of removal of heat from tool chip interface is reported by researchers [1-5].
Researchers use water based coolant in conventional cooling method, mixture of oil or water based coolant with air
passed thorough controllable flow in minimum quantity lubrication (MQL), use of cryogenic coolant like CO2, LN2,
etc in cryogenic technique, use of oxygen, helium and nitrogen in air cooling, use of multi-walled carbon nano tubes
(MWCNT), Ni nanowires, Al2O3 nano-particles, mix of MoS2+CNT in nano machining of metals.
For achieving good machinability of metal with suitable cooling technique is result in reducing cutting
temperature, improve properties of tools, increasing material removal rate, lowering of energy consumption, etc.
In this paper study of various cooling systems and their performance effect in turning, milling, grinding, etc. have
been studied. It is found that cooling with cryogenic liquid and nano-machining are most significant followed by
MQL and air cooling. Furthermore, the effect of cutting temperature on the performance of tool is discussed for the
selection of best cooling system in machining of ferrous and non- ferrous metals. The no use of coolant in machining
of metals and their effects are discussed in next section.

2. Dry cutting

The metal removal is performed in absence of coolant known as dry cutting or dry machining process. In dry
cutting operation, the main causes of tool wear are high cutting temperature, formation of built up edge, high
thermal shock, geometrical deviations in machined parts, etc. lead to increase of tool wear resulted on quality of
machined surface [6-11].
In dry machining higher cutting temperature is developed at high cutting speed which reduces strength of
work piece material also causes lower cutting force at cutting region. At high cutting temperature, the risk of
adhesion and diffusion wear due to chemical reactivity between the work piece and cutting tool material was
observed by [1] which diminished the life of tool. However, dry machining is preferred especially in terms of
environment sustainability and cost savings purpose. The dry cutting process must conserve the surface integrity of
work piece and bring out steady tool wear suitable for machining [12]. Researchers discussed the effect of cutting
fluid methods which categorized as indirect heat dissipation and enhancing properties of cutting tool using best tool
materials. The cutting tools with high refractivity, high hot hardness and low coefficients of friction are much useful.
Though, the application is limited due to geometrical restrictions of cutting tools and machining difficulties. The
tool coatings such as cubic boron nitride (CBN), polycrystalline cubic boron nitride (PCBN), polycrystalline
diamond (PCD), ceramics etc. are prominently used in dry machining [1]. Therefore, in modern tool technology the
expensive tool is not badly affected by heat alone and helps drastically in cutting process.

2.1 Effect on cutting temperature and tool life

In dry cutting process, metal-to-metal contact occurs and high cutting temperature is generated among chip-work
piece interface. The cutting tools are subjected to an extremely severe rubbing process. Hence, the tool coatings play
a major role in machining processes [13]. Titanium based hard coatings like TiN, TiCN, TiAlN with properties of
high hardness, high friction coefficient and high wear resistance are preferred in machining. Use of Al2O3 and ZrO2
PVD coatings showed best result in machining of cast iron [13]. A solid lubricant such as MoS2/titanium composite
coatings is used to reduce the friction coefficient and consequently high temperatures and resulted in low wear rate
as compared to hard coatings. Therefore, for improving tool life, solid type of lubricant coating was proposed for
dry machining [14].
As shown in Table 1, it is concluded that dry machining of metals is preferred over wet machining for the
enhancement of sustainability as shown in Fig. 1. However, dry machining is not suitable at high cutting speed and
hence to improve machinability the use of coolant is recommended by researchers [12]. The next part of paper
focuses on use of different cooling methods in machining of metals.
 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031 5021

Fig.1. Benefits of adopting dry machining [15].

Table 1. Dry machining of metals

Author Work piece Cutting tool Operation Effect
Basim and Nickel Cemented Turning Cutting speed significantly affected the surface finish values in
Bashir (2010) based carbide related with the tool insert geometry.
[16] alloy tool Insert type CCMT-12 showed better surface finish for cutting speed
up to 201 m/min. However, surface roughness is increased with
CNGN-12 insert type.
Schulz et al. SGI70 Carbide Drilling In dry drilling, the TiAlN–ZrO coating shows the best performance.
(2001) [13] Using oxide coating, temperature at the cutting edges is reduced.
Dudzinski et al. Inconel- Carbide Milling Higher cutting speeds (200 to 700 m/min) attained by ceramic tools.
(2004) 718 tools and The Al2O3–TiC coated tool is most stable and it has most thermal
[12] ceramic resistance in high speed machining.
tools
Shokrani et al. Inconel Solid Milling 33-40% reduction in Ra and Rz and 1.9% increase in power
(2012) 718 carbide consumption compared to dry machining.
[1] (TiAIN) Tool failure due to chipping and facture of tool nose.

Kadirgama et Haynes Carbide Milling TiAlN tool performed better in dry cutting compared with TiN/MT-
al. (2010) [17] 242 cutting TiCN/TiN tool.
tool TiAlN performed more superior with using water soluble coolant.

Satyanarayana Inconel Tungsten Turning Predicted optimum cutting parameters

et al.(2012) 718 carbide Obtained the best possible surface roughness with minimum cutting
[18] tool forces.
Sensitivity test was also conducted to study the influence of cutting
parameters.

3. Conventional cooling system

Cutting fluid is a type of lubricant designed for ease of metal cooling processes shown in Fig. 2. Conventional
cutting fluids are classified into three major categories as shown in the Fig. 3 such as oil-based (mineral oils, animal
oils and vegetable oils), gas based and aqueous based fluids, etc. For improving the efficiency in machining, water is
generally used as a favorable coolant. Due to low cost and functionality of conduction of heat, water based fluids are
preferred [19]. However, in some cases water is not effective coolant in metal removal process and lowered the
machinability. Therefore to overcome these issues some additives are added in water to make the efficient cooling.
At cutting zone, the excess amount of heat is generated caused by friction. Hence, oil based lubricants provides
cushioning effect at tool-chip interface. The application of oil is limited to low duty machining of easy to cut
materials, such as aluminum, magnesium, brass, low carbon steels, etc. [1]. In case of gaseous fluids, compressed
gas is used. In heavy duty cutting conditions, these compressed gas based coolant or cooled pressured fluids are used
for cooling purposes.
5022 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031

3.1 Effect on cutting temperature and tool life

Conventional cooling reduces temperature at tool-chip interface. The cooling system is especially suitable for
threading, broaching, tapping and gear hobbing operations [3]. By reducing tool mechanisms such as diffusion,
abrasion, etc. lead in reduction of mechanical wears. Thus, reduction in temperature results decrease in wear rate
and increase in tool life [12].
.

CUTTING
FLUIDS

Oil Gas Aqueous

based based based

Mineral Vegetabl Animal Solution Emulsion (oil

oils e oils oils (water in oil) in water)

Synthetic Semi-synthetic
cutting fluids cutting fluids
Fig. 2. Conventional cooling
Fig 3. Conventional cooling [2]

Table 2. Use of conventional cooling in machining

Author Work piece Cutting tool Operation Effect
Criado et al., Inconel 718 Polycrystalline Finishing PCBN tool performed better at lower cutting speed and
(2018) [21] cubic boron operation higher feed (250m/min and 0.15mm/rev).
nitride (PCBN) The life of the tool increases at low cutting speeds,
however the feed does not affect significantly.

Lopresto et Unidirectional High Milling The fiber orientation respect to the cutting direction
al., (2017) carbon speed steel determines the mechanisms of chip formation and
[22] (HSS) influences the cutting quality
Gajrani et al., AISI H-13 Carbide Turning 1:16 emulsion composition of developed green cutting
(2018) [23] steel. fluid was found to be optimum in terms of its better
thermal conductivity, specific heat as well as its storage
stability as per ASTM D 3707 standard.

Agrawal and M2 Steel Carbide Turning Surface roughness using aloe vera oil is lower by 6.7%
Patil, (2018) as compared to conventional cutting fluid.
[24] Tool wear using aloe vera oil is lower by 0.14% as
compared to conventional cutting fluid.

It is observed that the conventional machining of metals is suitable for medium - high speed machining process. As
a result the reduction of cutting temperature and improvement in tool performance is reported by researchers as
shown in Table 2. However, conventional machining is not very efficient as much liters of waste fluid is generated,
which ultimately spoils the environmental properties. Cutting fluids provide dermatological ailments to operator’s
 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031 5023

health coming in fumes, smoke, physical contact, bacteria, and odors. Additionally, requirement of extra floor space
and systems is required for pumping, storage, filtration, recycling and chilling of coolant [20]. These drawbacks are
associated with flood cooling. The next section discusses how cryogenic cooling techniques are used in machining
of metalsCryogenic cooling in machining
In physics, cryogenics means behavior of materials at low temperatures. In this technique, low temperature
coolants like CO2, LN2, etc. are used, termed as cryogenic coolant or cryogen [25, 26]. Boiling temperature of
permanent gases such as Nitrogen, Helium, Hydrogen, Neon, Oxygen, air is lie below -1800C [20]. For cooling
purposes, cryogenic liquids have a variety of applications such as manufacturing, medical, automotive and
aerospace industries.
Cryogenic coolant is mainly used in metal removal operations also known as cryogenic machining. There are
various cryogenic techniques used, one of them is using spray cryogen like Liquid Nitrogen (LN2), Liquid Carbon
dioxide (CO2), Liquid Helium are some cryogenic coolants used in metal removal processes at the point of cutting
[27]. Researchers reported, at the chip-tool interface temperature is reduced by spraying of cryogen. They used
different methods for cooling by using LN2 in machining for decreasing the temperature at the cutting zone,
dispersing the heat, cooling of tool and maintaining the properties of tool. The interaction between the work-piece
and cutting tool depends on the temperature of the cryogen and the chemical reactivity of the tool. Cryogenic
cooling increases the hardness of cutting tool, enhances their wear resistance properties, and reduces the coefficient
of friction result in better tool life Machinability of various alloys like titanium, nickel, aluminum composites,
polymer and ceramic materials is improved using cryogenic technique [28]. At a high feed rate chip thickness is
higher and faster rate of plastic deformation at the shear zone generating more heat Cryogenic cooling is more
effective at a high feed rate rather than higher depth of cut [29]. The functions of cryogenic cooling are removing
heat effectively from cutting zone, changing the properties of work piece and tool materials [30].

4.1 Effect on cutting temperature and tool wear

The applications of cryogenic coolant in machining of metals showed significant effect in terms of cutting
temperature and tool wear as shown in Fig 4. [31]. Kaynak et al. [30] reported reduction of cutting temperature and
tool wear using LN2 spray in machining process. Khan et al. [29] performed turning of stainless steel-SUS 304 using
TiCN coated tool. They reported effective cooling of cutting edge and improvement in tool life using modified tool
with cryogenic coolant. Sadik et al. [32] achieved wet and liquid CO2 in milling of titanium alloy (Ti-6AI-4V) using
Coro Mill 600-040Q16-12H equipped with coated inserts. The flow rate of coolant has limited influence on the rate
of flank wear development. The main type of wear determining tool life is notch wear, irrespective of the nature of
the coolant. They finally reported reduction of tool wear in cryogenic machining compared to conventional flood
emulsion.
Dhananchezian and Kumar [33] prepared modified multi coated carbide tools in turning of steel (AISI 1045). The
modified insert used for cryogenic cooling reduced the cutting temperature by 47 - 58% over wet machining.
Besides, cryogenic cooling decreases the cutting force by 27% over wet machining and reduced the surface
roughness to 25 -38% compared to wet machining. Kaynak et al. [30]; Deshpande et al. [34, 28] used cryogenically
treated and untreated tools in machining of Inconel 718- Nickel based supper alloy. They reported that, metallurgy
of the tool material along with mechanical and thermal properties are significantly improved by cryogenic treatment
of the tool. The product quality, tool life and material removal rate is enhanced using treated tool besides the
decrease of cutting temperature, cutting forces and tool vibrations.
It is concluded from Table.3, the use of cryogenic cooling techniques in cutting process improve the
machinability of metals. It is also suitable for high speed machining of difficult to cut materials. The dramatic
reduction of cutting temperature and improvement in tool life is reported by researchers [34, 29, 32, 35, 36, 37 ].
Also, cryogens are evaporated during machining which ultimately improve the environmental conditions. However,
high set up cost and more precautions are required while implementation of cryogenic cooling set up. The next
section discusses use of minimum quantity lubrication in machining of metals.
5024 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031

Table 3. Use cryogenic cooling in machining

Author Work piece Cutting tool Operation Effect
Deshpande et Inconel718 Carbide Turning As product quality and tool life is increased,
al.(2017) [28] tools sustainability benefits make cryogenic cooling more
profitable.
The metallurgy of the tool material along with
mechanical and thermal properties are improved by
cryogenic treatment of the tool.
Dhananchezian Steel Multi Turning The modified insert used for cryogenic cooling reduced
and Kumar (AISI 1045) coated the cutting temperature by 47 - 58% over wet
(2011) [33] carbide machining.
Cryogenic cooling decreased the cutting force by 27%
over wet machining.
Deshpande et Inconel 718 Carbide Turning Cryogenic machining with liquid nitrogen jet reduced
al.(2018) [34] the surface roughness to 25 -38% over wet machining

Devaraju and Aluminium H13 tool Milling It is observed that micro hardness increases up to 164
Kishan(2011) alloy steel HV higher than received aluminum alloy (138 HV).
[37] stir welded
2014-T6
Khan and Stainless steel AC2000, Turning The modified tool used for cryogenic coolant flow
Mirghani (2008) SUS 304 coated provides an effective means for cooling the cutting
[29] with TiCN edge during machining operation.
The application of cryogenic coolant using the
modified tool can increase tool life.
Sadik et Titanium alloy Cutter Wet Milling Tool life is not determined by flank wear in either
al.(2016) [32] (Ti-6AI-4V) (CoroMill cooling condition (CO2 or emulsion).
600- The flow rate of coolant has limited influence on the
040Q16- rate of flank wear.
12H) The main type of wear determining tool life is notch
wear, irrespective of the nature of the coolant.
Tapoglou et Titanium alloy End mill Milling The best performance at 100 m/min was achieved
al.(2017) [35] (Ti-6Al-4V) inserts using flood emulsion coolant, which easily achieved a
tool life of 30 minutes.
The best performing cryogenic method was CO2 plus
MQL which achieved a tool life of 18.5 minutes in
equivalent testing.
Hardt et al. Titanium alloy Cemented Turning The surface roughness of machined part found to be
(2018) [39] (Ti-6Al-4V) carbide smaller than Ra = 1 μm. The smallest surface
roughness was found to be Ra = 0.27 μm.
The surface hardness of the cryogenic machined
samples was found to be higher than the materials bulk
hardness. An increase up to 16.5 % was measured.

Fig. 4. Experimental setup for cryogenic cooling [38]

Fig. 5. Set up of MQL system [50]
 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031 5025

4. Machining with Minimum Quantity Lubrication (MQL)

Minimum Quantity Lubrication (MQL) or near to dry machining is a concept running since years ago associated
with airborne cutting fluid particles, and addressing the issues of occupational hazards and environmental
intrusiveness. Enormous efforts were made to reduce the use of lubricant by the researchers to discover this
technique which will act in both sides as coolants as well as lubricant used in minimum quantity. The mixture of
coolant and pressured air in the form of controlled flow is delivered through the tubing and nozzle to the cutting
point. MQL is used in industries at a range of 10-100 ml/h in machining of various metals shown in Fig 5. Coolant-
lubricant evaporates at the cutting zone which eliminates the maintenance, circulation and disposal of cutting fluid
[1]. The machining parameters improved using minimum quantity lubrication are surface roughness, cutting forces,
cutting temperature and tool wear and different studies performed by researchers are tabulated in Table 4.

Table 4. Use of Minimum Quantity Lubrication (MQL) in machining

Author Work piece Cutting tool Operation Effect
Ali et al. Medium carbon Uncoated Tuning Reduction of average chip tool interface temperature
(2011) [42] steel carbide insert depending upon the work materials, tool geometry and
cutting conditions.
It provided proper lubrication that minimizes the
friction resulting in retention of tool sharpness for a
longer period.
Barros et al. AISI 4340 steel CBN Grinding Flood coolant produces better surface roughness.
(2014) [43] rings Flood coolant is responsible for removing chips from
the cutting zone.
MQL provides efficient lubrication in able to control
the thermal deformation occurring on the work piece
and able to give good surface quality.
Emami et al. Aluminum Grinding wheel Grinding Use of optimally designed MQL in grinding reduced the
(2014) [44] ceramic tangential as well as normal grinding force and surface
roughness.
Hadad et al. Hardened 100Cr6 Grinding Surface Roughness improved using MQL than dry
(2015) [45] 100Cr6 condition.
Moreover MQL reduces grinding force which lowers
heat generation in contact zone.
Mello et Ti-6Al-4V Silicon carbide Grinding MQL shows lesser surface roughness and better surface
al.(2017) [46] alloy quality in lesser depth of cut. At higher depth of cut,
flood outperformed MQL
Rodriguez et ABNT 4340 Aluminum Grinding
al. (2017) steel oxide MQL with lower flow rate than 120ml/h exhibited
[47]
inferior performances in terms of high surface
roughness, higher wheel wear and more power
consumption.
Anand et al. Zirconia Silicon carbide Grinding
(2017) [48] MQL reduces grinding force and lesser wheel warns
out. The surface finish and G-ratio was better in wet
condition.
Rahim et al. AISI 1020 White alumina Grinding Use of MQL reduces surface temperature than flood
(2014) [51] oxide coolant.
MQL also helps in reduction of temperature which
attributed to the capability of the tiny mist particles of
MQL penetrating into the grinding zone, subsequently
reduces the grinding friction
5026 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031

5.1 Effect on cutting temperature and tool wear

Reduction in tool hardness and rapid tool wear is the main cause of machining of hard to cut materials; heat is
generated due to friction of cutter against work piece [40]. In the chips the heat is entered through the cutting zone,
then it goes to the tool and then work piece and lastly vanishes into the environment. In MQL system, a small
amount of vegetable oil or biodegradable synthetic ester is sprayed to the tool chip interface with compressed air
[41]. Deshpande et al. [34] stated that a compressed air provides the cooling and allows chips away from cutting
zone. Besides micro oil droplets promote a cushioning effect between tool and work piece surface. It is concluded
from Table 4, this technique is the solution for reduction in cutting temperature, tool wear and surface roughness
while maintaining cutting forces at reasonable levels [42, 41, 43, 44, 45, 46, 47, 48, 49 ].

Table 5. Machining with nano fluid

Author Work piece Cutting tool Operation Effect
Prabu and AISI D2 tool Carbon nano Grinding Using carbon nano tubes the surface characteristics
Vinayagam steel tubes (CNT) were improved from micro level to nano level.
(2010) [58]
Sahu et al. Ti-6AL-4V Carbide Turning Machining performance of nano fluid is confirmed at
(2017) [59] low cutting speed of 90 m/min. Nano fluid
outperformed conventional cutting fluid with 34%
reduction in tool wear, average 28% drop in cutting
forces and 7% decrease in surface roughness at cutting
speed of 150 m/min.
Vasu and EN-31 Steel Aluminium Grinding Surface roughness and heat penetration were decreased
Kumar oxide with addition of Al2O3 nanoparticles.
(2011) [60]

Sinha et al. Inconel 718 Aluminium Grinding Application of nano fluids resulted in minimization of
(2017) [61] oxide grinding forces, coefficient of friction, and
improvement in the ground surface integrity.

Shen et al. Cast iron Aluminium Grinding Nano fluids showed the benefits of reducing grinding
(2009) [62] oxide forces, improving surface roughness, and preventing
work-piece burning.

Setti et al. Ti-6AL-4V Single point Grinding

(2012) [57] diamond dresser Grinding forces reduced significantly when nano
cutting fluid was used even at low concentration of the
nano particles and surface finish has been found to
improve with higher concentration of the nano particles.

5. Machining with Nano fluid

In recent years, remarkable improvement is shown by the inclusiveness of nanoparticles presented in Fig. 6 [52].
Nano fluid offers heat transfer capabilities, reduction in coefficient of friction, wear effect to enhance the efficiency
and reliability of machined parts. For improving the properties of lubricants or coolants, nano-size solid particles are
dispersed into the base fluids such as water, lubricating oils, etc. Excellent properties of the Nano-fluid can be
beneficial for cooling and lubricating in machining [53]. Coefficient of friction can also be improved by
implementing the Nano lubricants. Mending effect is achieved by the deposits made by the nano particles on the
friction surface [53].
 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031 5027

6.1 Effect on tool wear

Friction force and the cutting force are increased due to tool wear by the friction force at the tool-chip interface
and tool failure occurred in dry machining. It has been studied that by proper use of cooling abilities of nano fluid,
rate of tool abrasion can be reduced [15, 54, 55 ]. Nano fluid reduces flank wear, because of convectional,
conduction, and wettability properties of cooling and lubricant [56]. Setti et al. [57] performed the grinding on Ti-
6Al-4V under nano fluid, based on Al2O3 and CuO nano-particles using MQL. They reported enhancement in
quality of machined surface using nano coolant in machining.
It is concluded from Table 5, by the applications of nano fluid in machining, tribe film is formed at the cutting.
Coefficient of friction is reduced and effective cooling is achieved due to ideal chip formation. Additionally, roller
effect is induced in the cutting zone by reduction of friction and improving heat transfer capacity using Al2O3 nano
particles. The efficient lubrication helps with decrease in hob wear, increase in tool life, enhance gear profile
accuracy, gear surface roughness.

Fig 6. Manufacturing the spur gear with nano

lubricant in hobbing machine [52] Fig 7. Experimental setup for air cooling [70]

6. Air cooling

Air cooling provides safe and environmental friendly machining, which has attracted many academic and
scientific researchers. In this process chilled and compressed air is used for cooling purpose described in Table 6 [1,
63, 64, 65, 66, 67]. High pressurized gases of oxygen, helium and nitrogen are generally used in air cooling system.
The set-up of air cooling is presented in Fig. 7.

7.1 Effect on cutting temperature and tool life

Researchers reported dry cutting produces higher cutting temperature, tool wear and surface roughness
compared to air cooling [1]. Sun et al. [67] used cooled and compressed air in turning of Ti64. They stated that
cutting forces is increased by using chilled air cooling but reduces tool wear and cutting forces in comparison with
dry machining. At elevated temperatures, wear mechanisms is increased which resulted reduction in tool life. Liu
and Kevinchou [68] studied the effects of cooled air by a vortex tube in turning of A390 aluminum using tungsten
carbide tool. They reported reduction in flank wear by 20%, at 5m/s cutting speed and feed of 0.055mm/rev using
cooled air. Furthermore, 7% reduction in cutting temperature, reductions in adhesion and BUE at cutting edges is
identified. Rahman et al. [69] resulted decrease in surface roughness in end milling of AISI P-20 steel with tungsten
carbide tool. At feed rate of 0.01mm/tooth air cooling produced a higher surface finish, while increasing feed rate
surface finish is lowered. Yalcin et al. [70] stated that air cooling of ductile materials is favorable as it provides
5028 S. Deshpande and Y. Deshpande/ Materials Today: Proceedings 18 (2019) 5019–5031

acceptable tool life and surface finish. Tool life is increased by using of chilled MQL in machining of Ti64 using
uncoated WC cutting tool. Best results of tool life and surface roughness were achieved with the temperature of -
1500C [64].

Table 6. Machining with air cooling

Author Work piece Cutting tool Operation Effect
Liu and A390 Uncoated WC Turning At the cutting speed of 5 m/s and feed rate of 0.055
Kevinchou aluminum tool mm/rev reduced the flank wear by 20%.
(2007) [68]
Sun et Ti-6Al-4V Carbide Turning Cutting forces is increased by chilled air cooling, but
al.(2010) [67] alloy reduction in tool wear and cutting forces in
comparison with dry machining
Rahman et al. AISIP 20 Sumitomo Milling End milling AISIP-20 steel with uncoated WC tool
(2003) [69] electric carbide produced lower surface roughness than flood
cooling.
Khairusshima Carbon fiber Carbide Milling Tool life of the carbide cutting tool was longer at the
et al.(2013) reinforced highest cutting speed (200 m/min) and feed rate
[70] plastic (CFRP) (0.05 m/rev) under air conditioning air coolant
machining compared with that under room
temperature machining.

7. Conclusion
In this paper, an attempt is made to identify different cooling techniques in machining process and their effect on
cutting temperature and tool life have been reviewed. No method is available to insure complete success in terms of
significant cooling in machining operations. The types of cooling techniques in machining are studied as: dry
cutting, conventional cooling, cryogenic techniques, minimum quantity lubrication (MQL), nano fluid machining
and air cooling. In dry cutting, high temperature is the main cause of tool wear resulting in tool failure. Therefore
presence of coolant is essential in machining. In conventional cooling, oil based, gas based and aqueous based
lubricants are used. Temperature is slightly reduced resulting in minimum tool wear. However, major drawbacks are
environmental and health impacts and waste fluid maintenance and disposal is problematic. In cryogenic technique,
cryogens like liquid nitrogen, liquid carbon-di-oxide, liquid helium are used as a lubricant. Exceptional
improvements are seen in terms of tool life and cutting temperature. Surface quality is also improved resulting in
better product life. MQL provides combined effect of coolant as well as lubricant, due to which set up and fluid cost
is reduced. Lubrication cools the cutting tool which reduces tool wear. In nano fluid machining, nano size particles
are dispersed in the base fluid. It has extraordinary performance in heat transfer, lubrication and wear effects. Its
properties make them attractive in cooling applications related to manufacturing. In air cooling, compressed air is
used as a coolant which enhances characteristics like tool wear, temperature and surface quality. It simplifies chip
breaking and removal, in reduced cost. The selection of appropriate cooling system is quite difficult, especially in
machining of difficult to cut materials. The present review definitely helps to machinist for selecting the relevant
type of coolant in machining of various metals at shop floor industries which would be beneficial for the
enhancement of productivity. Thus, cooling techniques can provide the best solution to the expanding need of
machining.

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