Abstract
In this study, a fundamental investigation on the effect of cutting fluid application and type of fluid on sawing I-beams was carried out. This research hypothesizes that the minimum quantity fluid system with the right coolant/lubricant can be an effective and a sustainable sawing solution for structural applications by reducing cutting forces and surface roughness. A 41 mm bimetal band saw blade with 4/6 TPI (variable tooth per inch) was used on an Amada horizontal scissor saw at a constant feed and speed to saw I-beams. The Saw Blade Lube System™ by UNIST was the minimum quantity fluid system used in this study, and the system was used as recommended by the manufacturers. Four different cutting fluid applications and coolant combinations, namely, dry, flood application using synthetic oil + water, minimum quantity application using biodegradable vegetable oil + compressed air (recommended by the manufacturer), and minimum quantity application using the synthetic oil + water, are studied. Surface roughness, micro-hardness, and sawing forces were recorded/measured and analyzed for all four cutting fluid conditions. Chip welding/built-up edge formation and flank wear were studied to understand the interactional effects of the cutting fluid applications. Based on the results, it is evident that lubrication is more important than cooling in sawing I-beam due to the interrupted nature of sawing. This study lays a road map for optimizing the cutting fluid application for band sawing.
