CUTTING FLUID APPLICATION FOR BANDSAWING: A SUSTAINABLE SOLUTION FOR CUTTING SOLIDS

The band saw cutting is one of the many cutting/machining operations that can benefit from cutting conditions and cutting fluid optimization. Optimizing cutting speed, feed rate, and cutting fluid application based on the cut material can increase the blade's life. Most of the academic and industry work focuses on optimizing the cutting tool design and cutting conditions such as band saw blade speed and feed rate. Most of the band sawing industry uses flood cutting fluid to reduce the cutting temperatures, remove chips, and (in some cases) act as a lubricant. There is a lack of comprehensive understanding of the role of cutting fluid, and its method of application in the band saw cutting. In this paper, cutting fluid application on the cutting performance metrics such as surface roughness, (feed) force, and cutting edge wear (at ten cuts) were studied. The study also focuses on the chip formation and cutting temperatures generated while cutting with and without cutting fluid application. A flood cutting fluid application (recommended for the D2 tool steel), varying amounts, and compositions of the minimum quantity cutting fluid applications were studied along with dry (or no cutting fluid application) cutting. D2 tool steel material was used as workpiece material, and a carbide-tipped band saw blade was used as the cutting tool. In general, the band saw teeth split the kerf to improve the cutting process through reduced cutting temperatures and forces. The cutting conditions influence the chip formation and kerf splitting process. The results show that the minimum quantity cutting fluid applications negatively influenced the cutting performance. They produced the highest feed forces and caused severe tooth damage compared to the other experimental conditions. The results concluded that dry (no cutting fluid application) is recommended for cutting D2 tool steel material. This road map can be used to improve the band saw blade life and improve the cut-surface roughness.