Performance Profiling of Boric Acid as Lubricant in Machining

Performance Profiling of Boric Acid

Nageswara Rao Damera
Andhra University
as Lubricant in Machining
Dept of Mechanical Engineering Turning is a widely used metal removal process in manufacturing industry that involves
Visakhapatnam, India generation of high cutting forces and temperature. Lubrication becomes critical to
minimize the effects of these forces and temperature on cutting tool and workpiece. The
conventional cutting fluids employed in machining have certain limitations with regard to
their use for ecological and economic reasons. Development of lubricants that are eco
Vamsi Krishna Pasam friendly is acquiring importance. In this context, application of solid lubricants has proved
[email protected] to be a feasible alternative to the conventional cutting fluids. In the present work, Boric
GITAM University Acid is used as a lubricant in turning process. Variations in cutting force, tool wear, tool
Dept of Industrial Production Engg temperature and surface roughness are studied under different machining conditions. The
Visakhapatnam, India
results indicate that there is considerable improvement in the machining performance with
Boric Acid assisted machining compared to dry and wet machining.
Keywords: turning, solid lubricant, boric acid

grinding. Different process parameters like cutting forces,

Introduction temperature, specific energy and surface roughness are observed and
reported to be reduced when compared to those in grinding with
1
Reduction of environmental pollution has been the main conventional coolant. In another study, it is shown (Deng Jianhua et
concern in the present day manufacturing industry. Increasing al., 2005) that the friction coefficient at the tool-chip interface in dry
pollution-preventing initiatives globally and consumer focus on cutting of hardened steel and cast iron with Al2O3/TiC/CaF2 ceramic
environmentally conscious products has put increased pressure on tool was reduced compared to that of Al2O3/TiC tool without CaF2
industries to minimize the use of cutting fluids (Tan et al., 2002). It solid lubricant.
is reported (Sreejith; Ngoi, 2000) that cutting fluids can pose serious Boric Acid (H3BO3) is one of the most popular solid lubricants
problems, the major ones being those related to preservation of the and has excellent lubrication properties without calling for
environment, workers’ health, etc. However, the use of lubricant expensive disposal techniques. The most important characteristics of
cannot be swayed away in view of the high temperatures and forces boric acid for use as a lubricant are that it is readily available and
generated during machining. The heat generated in machining environmentally safe. The Environmental Protection Agency has
adversely affects the quality of the products. As an alternative to the established that boric acid is benign and the Clean Water Act does
conventional cutting fluids, researchers experimented with not classify it as a pollutant. Several studies related to the
biodegradable and cryogenic coolants (Brinksmeier et al., 1992) lubrication properties of boric acid are carried out over the past
(Inasaki et al., 1993), in order to reduce the heat generated in several decades (Peterson et al., 1960) (Johnson; Sliney, 1962)
machining zone by reducing the coefficient of friction and tool (Erdemir, 1991) (Erdemir et al., 1991) (Erdemir et al., 1997)
wear. The effectiveness of cryogenic coolant seemed to increase at (Erdemir et al., 1999). These works have primarily focused on the
higher feeds. It reduced the magnitude of tensile residual stress for performance of boric acid in high temperature applications. The
all materials, although to varying degrees, under all feed levels. This studies indicated that boric acid’s unique layered inter-crystalline
was attributed to the efficient cooling action, better modes of chip structure makes it a very promising solid lubricant material because
formation, less specific energy and finally, lower grinding zone of its relatively high load carrying capacity and low steady state
temperature (Paul; Chattopadhay, 1996). The concept of minimum friction coefficient (0.02). Another study focused on the use of boric
quantity lubrication (MQL) was also employed as an alternative acid as a lubricant in manufacturing processes such as forming and
approach. A study has been carried out in the area of eco-friendly drilling. In metal forming applications (Erdemir, 2008) (Wei et al.,
sustainable manufacturing using clean machining processes utilizing 2000) (Rao; Wei, 2001), it is shown that boric acid provided very
minimum quantity of lubricant such as MoS2 powder and grease low friction between an aluminium workpiece and a steel forming
based graphite mixed with water and SAE 20 oil in various tool. During these processes, the post-fabrication cleaning of boric
proportions instead of flooding coolant (Bagchi et al., 1972) acid was environmentally safe, non-toxic and water-soluble. In an
(Lathkar; Basu, 2000). Advances in modern tribology have earlier work by (Liang; Jahanmir, 1995), drilling experiments with
identified several solid lubricants, which are promising for sapphire tools indicated that the addition of boric acid to distilled
sustaining and providing lubricity over a wide range of water increased the rate of drilling of polycrystalline alumina by a
temperatures. Most of these lubricants, which include graphite, factor of two. In addition, boric acid was found to help in reducing
molybdenum disulphide, tungsten disulphide and calcium fluoride, friction and corrosion when mixed with cutting and grinding fluids
belong to a special class of materials known as lamellar solids. (Branneen et al., 1990) (Rekow et al., 1993) during machining
Researchers (Venugopal; Venkateswara Rao, 2004) investigated the processes. It is very important to note, however, that the success of
use of graphite as a lubricating medium while grinding SiC to boric acid in each of the above studies was dependent on the
reduce the heat generated in the grinding zone. The tangential force continuous replenishment of boric acid into the contact region.
component and hence, the specific energy requirement is found to In the present work, Boric Acid is used as solid lubricant during
be considerably reduced using graphite as a solid lubricant. The turning of EN8 steel using HSS and carbide cutting tools. Tool
effective role of graphite as lubricant was evident from the overall wear, Cutting forces, Cutting temperatures and surface roughness
improvement in the process. Researchers (Shaji; Radhakrishnan, were measured during machining. Cutting tests carried out under
2003) investigated the possibility of using graphite as a lubricating dry and wet conditions were compared with those carried out with
medium to reduce the heat generated in the grinding zone in surface solid lubricant. Particular attention was paid to the application of
solid lubricant in a continuous and uniform manner throughout
machining.
Paper accepted March, 2008. Technical Editor: Anselmo Eduardo Diniz.

J. of the Braz. Soc. of Mech. Sci. & Eng. Copyright © 2008 by ABCM July-September 2008, Vol. XXX, No. 3 / 239
 D. Nageswara Rao and P. Vamsi Krishna

Experimental Work Finally, a magnetic separator is used to separate fine metal particles
from solid lubricant powder. This system allows the powder to be
Number of variables affects the machining performance, the reused.
important parameters being the cutting conditions, tool geometry
and type of lubricant. In this study lubricating condition is selected
for experimental condition. Experiments are conducted under dry,
wet and solid lubricant conditions to study the cutting forces, tool
wear, tool temperature and surface roughness in turning. The
experimental details are presented in Table 1. Cutting velocity and
feed rates are selected based on the tool manufacturer’s
recommendations for workpiece material and tool combination
(HMT, 1998).
The cutting forces are measured with calibrated strain gauge
dynamometer. The tool wear is measured off-line at the end of each
cut under 30 x enhanced. The temperature is sensed by the
embedded thermocouple (Venkatesh; (Chandrasekaran, 1982)
(Srinivasa Rao et al., 2006). A thermocouple is placed at the bottom
of the tool insert in the tool holder as shown in Fig. 1. The
temperature measured by the thermocouple is only a representative
figure for comparison purpose as this does not measure the cutting
zone temperature. Calibration of the thermocouple is carried out in a
water bath with a thermometer and a maximum of 2oC difference is Figure 2. Experimental setup showing the powder feeder.
noted over a range from 40oC to 95oC. Talysurf is employed for
measuring average surface roughness (Ra).

Figure 1. Tool holder with provision for thermocouple.

Figure 3. Powder feeder attached to tool post.

Flood coolant is applied at the rate of 0.11 m3/min. The

experimental setup developed for machining with solid lubricant
powder is shown in Fig. 2. The solid lubricant powder is fed to a
container attached to the tool post of the machine as shown in Fig. 3.
The outlet of the container is connected to one end of a T-joint pipe
while other end is facilitated with a convergent nozzle used for the
flow of compressed air as shown in Fig. 4. Compressed air while
passing through the nozzle creates low pressure at the T junction
that sucks the powder along with self weight of the powder and
allows it to flow freely through the other end. The outlet of T
junction is arranged in such a way to ensure that solid lubricant
powder flows continuously to the machining zone. After ensuring
the setup for proper flow experiments are conducted in triplicate.
Average of the results is considered and taken as the final value to
compensate for the discrepancies in the process, if any. For
economic viability, trial is done at low mass flow rates. The entire
machining operation using solid lubricant powder is carried out in a
closed chamber so that powder particles are not allowed to mix
freely in air. A solid lubricant powder recovery system is used to
reduce waste. This system contains a sieve to separate solid Figure 4. Powder flow arrangement through T-junction pipe.
lubricant powder from chips produced during machining process.

240 / Vol. XXX, No. 3, July-September 2008 ABCM

Performance profiling of Boric Acid as lubricant in machining

Table 1. Experimental conditions.

Work specimen
Material: EN 8 steel (C = 0.36-0.45%, Mn= 0.6-1%, Si= 0.2-0.3%, S = 0.025%, P=0.015%)
Size (mm): Ø50×400mm
Hardness: 30±2 HRC, heat treated

Process parameters
Cutting velocity: V= 40 m/min (HSS Tool), V=65m/min (Carbide Tool)
Feed rate: S= 0.2198mm/rev (HSS Tool), S= 0.2514 mm/rev (Carbide Tool)
Depth of cut: t= 1.0mm
Environment: Dry, wet (flood cooling) and solid lubricant (graphite, boric acid)
Flow rate of solid lubricant: 2-3gm/min
Air compressor pressure: 0-3kg/cm2

Machine tool
Lathe Machine: (PSG Company, INDIA)
Motor capacity: 10hp
Cutting tool (insert): Carbide- SNMG 120408 (ISO specification), HSS.
Tool holder: PSRNR 12125F09 (ISO specification)

Working tool geometry

Inclination angle: −60
Orthogonal rake angle: −60
Orthogonal clearance angle: 60
Auxiliary cutting edge angle: 150
Principle cutting edge angle: 750
Nose radius: 0.8 (mm)

Lathe Tool dynamometer

Make: Lakshmi Controls and Instruments, INDIA.
Measuring range: 0-2000 N
Type: Cantilever type strain gauge dynamometer
Accuracy: 2%

Thermocouple
Designation: K type, Shielded Thermocouple.
Element outside diameter: d: 2mm.
Element Length: L: 120 mm.
Element Type: Duplex.
Sheath material: Recrystalised Alumina.
Temperature Range: -250oC- 1260oC.
Tolerance: ± 2.2o C or ± 0.75% (Whichever is greater between 0 oC -1250oC).

Results and Discussion This performance of boric acid is due to its lattice layer structure
allows it to act as an effective solid lubricant film. Crystallized boric
A comparative performance analysis of the solid lubricant acid forms weak Vanderwall bonds between individual layers and
application with dry and wet machining is done. Fig. 5 and Fig. 6 strong hydrogen (covalent) bonds within the layer. Such a bonding
show the variation of main cutting force and longitudinal feed force structure makes the structural properties of boric acid highly
with cutting time while machining under three different conditions anisotropic. When tangentially loaded, the individual lamellae slide
for a period of 30min each. Results show that the cutting force is relatively easily over one another. This is in contrast to the normal
considerably less with application of solid lubricant compared to dry direction where the boric acid has a relative high load carrying
and wet machining. The lubricant effectiveness in minimizing the capacity. Hence, when properly aligned with substrate, boric acid
frictional affects at the tool and workpiece interaction in case of will exhibit minimal friction and provide effective separation
solid lubricant assisted machining is evident from the reduced between surfaces.
cutting forces compared to that of dry and wet machining.

J. of the Braz. Soc. of Mech. Sci. & Eng. Copyright © 2008 by ABCM July-September 2008, Vol. XXX, No. 3 / 241
 D. Nageswara Rao and P. Vamsi Krishna

900 0.5
800
Dry-HSS
Main Cutting Force, N

0.4

Flank wear, mm
70 0
Cutting Fluid-HSS
0.3 dry
600 Boric Acid-HSS
powder
50 0 Dry-Carbide 0.2 coolant
400 Cutting Fluid-Carbide
0.1
300
Boric Acid-Carbide
0
200
0 10 20 30 40 0 10 20 30 40
Machining T ime, mins Machining time, mins

Figure 5. Variation of main cutting force with machining time. Figure 7. Variation of flank wear with machining time (HSS tool).

250 0.4
Longitudinal Feed Force, N

Dry-HSS
200 0.3

Flank wear, mm
Cutting Fluid-HSS dry
Boric Acid-HSS 0.2 powder
150
Dry-Carbide coolant
Cutting Fluid-Carbide 0.1
100
Boric Acid-Carbide
0
50
0 10 20 30 40
0 10 20 30 40

Machining Time, mins Machining time, mins

Figure 6. Variation of longitudinal feed force with machining time. Figure 8. Variation of flank wear with machining time (Carbide tool).

Figure 7 and Fig. 8 show a comparison of flank wear while Figure 9 and Fig. 10 compare tool temperature measured at
machining in the three different conditions. Flank wear is observed nodal point against cutting time for all the three cases. Temperature
to be considerably less in Boric Acid assisted machining for both the is lower in case of Boric Acid assisted machining compared to dry
tool-work combinations. During cutting process the chip slides machining. The result is implied by the low coefficient of friction as
against the tool rake face at a high speed, and induces high cutting Boric Acid dehydrates above 1700C and softens at about 4000C. The
temperature. The effectiveness of the solid lubricant in any context lubricating action of the solid lubricants reduces the frictional forces
is strongly affected by temperature, pressure, speed and between the chip and tool interface and tool and the workpiece.
environmental conditions; in the present case, cutting temperatures, Hence, temperatures developed in case of solid lubricants are
cutting forces, cutting conditions and ambience. Under such high reduced compared to dry and wet machining. As the film formation
cutting temperature, the solid lubricant may melt and smear creating on the surface of the workpiece and lubricating action of the solid
a thin lubricating film on the rake face of the tool. The substantial lubricant significantly depends on temperatures developed in the
reduction of flank wear observed is due to the low coefficient of process, variation of the temperature on cutting tool presented is
friction and sliding action. Low shear resistance within the contact only for the selected cutting conditions and tool-work combination.
interface is also one of the reasons for reduction of flank wear. Though not much difference is observed in the temperatures while
Three important properties of the solid lubricant i.e. low friction machining with cutting fluid or Boric Acid as lubricant, the non-
coefficient, sliding between layers and low shear resistance are due polluting nature of Boric Acid is a clear advantage and a critical
to its lamellar structure only. Hence, lubricating action of this parameter in making the choice.
lamellar solid mainly depends on cutting conditions and tool-work
combinations.

242 / Vol. XXX, No. 3, July-September 2008 ABCM

Performance profiling of Boric Acid as lubricant in machining

12 0 900

800
Tool Temperature, 0C

Main Cutting Force, N

10 0
70 0

80
dry
600 HSS
pow der
60 50 0 Carbide
coolant
400
40
300

20
200
0 10 20 30 40
0 0 .1 0 .2 0 .3 0 .4
Machining T ime, mins Flank Wear, mm

Figure 9. Variation of tool temperature with machining time (HSS tool). Figure 11. Variation of main cutting force with flank wear (boric acid).

16 0 2 50

Longitudinal Feed Force, N

14 0
Tool Temperature, 0C

200
12 0
dry
10 0 HSS
powder 150
80 Carbide
coolant
60
10 0
40

20 50
0 10 20 30 40 0 0 .1 0 .2 0 .3 0 .4

Machining Time, mins Flank Wear, mm

Figure 10. Variation of tool temperature with machining time (Carbide Figure 12. Variation of longitudinal feed force with flank wear (boric acid).
tool).

Variation of cutting force with flank wear in Boric Acid assisted

machining is shown in Fig. 11 and Fig. 12. Cutting force increases 5
Surface roughness Ra, microns

with flank wear both in HSS and carbide tools. This may be
attributed to increase in temperature with machining time, which 4
leads to flank wear thus requiring higher specific energy and cutting
force for material removal. Though the value of flank wear is 3
different in both cases, the trend of cutting force variation with flank Series1
2
wear is the same. As tool wear is less in case of boric acid assisted
machining compared to dry and wet machining, cutting forces tend 1
to be lower with boric acid as lubricant.
Figure 13 and Fig. 14 compare surface roughness of the 0
machined surface in the three conditions. The results indicate better dry cutting fluid boric acid
surface finish with Boric acid, while machining with either of the
tools, demonstrating its effectiveness. This could be due to the
reduction in the cutting forces. The decrease in surface roughness Figure13.Surface Roughness (Ra) for different lubricants (HSS Tool).
due to boric acid can be attributed due to the inherent lubricating
properties even at high temperatures. The lubricating action of the
Boric Acid reduces the frictional forces at the tool, workpiece and
chip interface. This decreases the temperatures at the cutting zone
and results in lesser tool wear, thus resulting in surface quality
improvement.

J. of the Braz. Soc. of Mech. Sci. & Eng. Copyright © 2008 by ABCM July-September 2008, Vol. XXX, No. 3 / 243
 D. Nageswara Rao and P. Vamsi Krishna

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