Effect of coolant strategy on tool performance, chip morphology and surface quality during high-speed machining of A356 aluminum alloy

This paper describes the results of application of different coolant strategies to high-speed milling of aluminum alloy A356 for automotive industry. The paper investigates the effect of flood coolant, dry cutting, and minimum quantity of lubricant (MQL) technologies on tool wear, surface roughness and cutting forces. The cutting speed range was up to 5225 m/min. The feed rate used was up to 20 m/min. The result of MQL application is compared with dry milling and milling with flood coolant application. It was found that the MQL technology could be a viable alternative to the flood coolant application. The adhesive tool wear mechanism and adhesion activated surface quality deterioration are revealed and the role of lubricant in their reduction is defined. (C) 2004 Published by Elsevier Ltd.