Enhancing the reliability and wear resistance of high-speed cutting tools through the use of ionized air-oil lubrication media in machine part restoration
DOI:
https://doi.org/10.31891/2079-1372-2025-118-4-72-78Keywords:
ionized air–oil medium, lubricating and cooling technological means, corona discharge, tribological studies, tool life, micro-dosed oil supply, friction and wear, industrial oil Mobil DTE 22, cutting machining, activated media, surface roughnessAbstract
A comprehensive analysis of the wear processes of high-speed cutting tools and methods of improving their performance during machining has been carried out in this work. An analytical review of scientific sources on modern methods of supplying lubricating and cooling technological means (LCTM) was performed, including the activation of air and air–oil flows and their influence on friction and cutting processes. Special attention is given to the micro-dosed supply of industrial oil Mobil DTE 22 in the form of sprayed air–oil mixtures activated by the electric field of a corona discharge. A nozzle device for the metered supply of viscous fluids with subsequent activation of the air stream has been developed and investigated, ensuring reduced operating pressure and improved operational safety. A tribometric test stand was designed and used to study the lubricating ability of activated LCTM and to determine the friction coefficients of various materials. It was established that ionized air–oil media significantly reduce friction torque, stabilize contact interaction, and decrease surface roughness. Experimental studies of the cutting process demonstrated a substantial increase in the tool life of high-speed steel cutters when using ionized air–oil flow: up to three times compared with dry cutting and up to 2.5 times compared with free oil flooding. The application of the desirability function enabled a comprehensive evaluation of the effectiveness of different LCTM options, showing an increase in machining efficiency of up to 40%.
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