Comparison among different vegetable fluids used in minimum quantity lubrication systems in the tapping process of cast aluminum alloy

Nowadays, cooling fluids are the great environmental issue, because they consume a considerable amount of water and can pollute natural water sources for decades when they are discarded and disposed of irregularly. Based on this, the Minimum Quantity Lubrication technique, that uses low amounts of fluids, has been used in drilling processes since 1990 and is a major breakthrough in reducing the use of cutting fluids. In this study, three different Minimum Quantity Lubrication cutting fluids were tested and compared with emulsions in cut and form tapping processes. A Full factorial design was performed to identify the significant effect of the type of oil, cooling/lubrication system and cutting/forming speed on the torque value of the tapping processes. A steering system carcass manufactured by A306 cast aluminum alloy was used as a workpiece in the tapping operations. The results showed that fluid A (ECOCUT) in the Minimum Quantity Lubrication system has a high potential to reduce torque value while minimizing the friction and can avoid that tools break, in some situations. Furthermore, form tapping was found to be a suitable alternative, since it does not generate chips, which reduces costs with recycling, storage, and waste disposal.