A comprehensive tool-wear/tool-life performance model in the evaluation of NDM (near dry machining) for sustainable manufacturing

Traditionally, metal working fluids (MWF) are known to improve machining performance despite poor ecological and health side effects. A new sustainable process that has minimized the use and application of MWFs is NDM (near dry machining). Although there is much controversy on the effectiveness of NDM, it is agreed that a lack of science-based modeling prevents its widespread use. This paper presents a new method to predict tool-wear/tool-life performance in NDM by extending a Taylor speed-based dry machining equation. Experimental work and validation of the model was performed in an automotive production environment in the machining of steel wheel rims. Machining experiments and validation of the new equation reveal that tool-wear can be predicted within 10% when the effect of NDM is statistically different than dry machining. Tool-wear measurements obtained during the validation of the model showed that NDM can improve tool-wear/tool-life over four times compared to dry machining which underlines the need to develop sustainable models to match current practices.