S/N NAME REG NO 1 Khadija Abdussamad Ismail ENG/21/MCT/00435 2 Oladimeji David Joseph ENG/21/MCT/00440 3 Jatto Osagie Godspower ENG/21/MCT/00434 4 Maryam Kabir Sheshe ENG/21/MCT/00440 5 Musa Simon Samaila ENG/22/MCT00602 6 Abubakar Sadiq Ahmad ENG/21/MCT/00432 TABLE OF CONTENTS INTRODUCTION IMPORTANCE OF CUTTING FORCES AND POWER FORCES ACTING DURING MACHINING MEASUREMENT OF CUTTING FORCES POWER AND ENERGY IN MACHINING TEMPERATURE EFFECTS AND HEAT GENERATION CUTTING FLUIDS FUNCTIONS OF CUTTING FLUIDS METHODS OF APPLYING CUTTING FLUIDS TYPES OF CUTTING FLUID SELECTION OF CUTTING FLUIDS CONCLUSION INTRODUCTION • Machining performance depends on cutting forces, power, and cutting fluids. Cutting forces impact tool wear, power consumption affects efficiency, and cutting fluids improve cooling and lubrication. Importance of Cutting Forces and Power Cutting forces influence tool life, surface finish, energy efficiency, and machine stability. Proper analysis helps in process optimization, reducing tool wear, and minimizing energy consumption. Forces Acting During Machining During machining, three main forces act on the tool and workpiece: Cutting Force (Fc): The primary force acting in the cutting direction. Thurst Force (Ft): Acts perpendicular to the cutting direction. Radial Force (Fr): Acts perpendicular to both Fc and Ft, affecting tool stability. Forces Acting During Machining Forces Acting During Machining Mathematically, these forces can be related using Merchant’s equations: Measurement of Cutting Forces Cutting and thrust forces are measured using a dynamometer. The force components are analysed using vector decomposition: Accurate measurement helps in optimizing cutting conditions and preventing excessive tool wear. Power and Energy in Machining Power consumption in machining is calculated using: Power and Energy in Machining Energy required per unit volume of material removal is given by: Temperature Effects and Heat Generation High cutting forces lead to heat generation at the tool-chip interface, affecting tool wear and workpiece integrity. Heat dissipation is governed by: Where 𝜇 is the coefficient of friction. Controlling temperature through optimized cutting speeds and cooling methods extends tool life. Cutting Fluids •Used in metalworking operations like cutting, drilling, milling, and turning. •Minimizes heat generation during machining. •Provides lubrication to reduce friction and wear. •Enhances tool life and improves surface finish. Functions of Cutting Fluid Cools the workpiece and cutting Lubricates the tool. Reduces cutting zone, heat, improving friction, and Helps remove efficiency. tool wear. Enhances machining speed and accuracy. chips and prevents tool damage. Protects against corrosion and reduces material adhesion. Methods of Applying Cutting Fluid Manual Application: Fluid is dispensed manually using an oil can. Flood Application: High-pressure fluid is delivered via hoses or nozzles. Mist Application: Cutting fluid is atomized and blown onto the workpiece. Types of Cutting Fluid Cutting Fluid Non-WaterBased Waterbased Soluble oils Semisynthetic Synthetic Straight oils Types of Cutting Fluid Soluble oils • Mixture of soluble oils, emulsifiers, and water (1%-20%). • Used for light cutting operations with low metal removal rates. • Common in milling aluminum to prevent adhesion and improve finish. Types of Cutting Fluid Semi-Synthetic Fluid • Combination of mineral oils and water. • Water alone is unsuitable due to corrosion. • Examples: Kerosene, motor oil. • Used in aluminum machining to prevent built-up edge formation. Types of Cutting Fluid Synthetic Cutting Fluid • Water-based, does not contain mineral oils. • Includes rust inhibitors to prevent corrosion. • Ideal for grinding operations requiring cooling and minimal residue. Types of Cutting Fluid Straight Oils • Pure vegetable or petroleum oils without water mixing. • Common in slow-speed broaching for high lubrication. • Examples: Paraffin oil, naphthenic oils, vegetable oils. Selection of Cutting Fluid The selection of a cutting fluid depends on factors such as the: Workpiece material Tool composition Type of machining operation The desired cooling and lubrication effect CONCLUSION Mastering cutting forces, power, and cutting fluids enables precise machining control, optimizing efficiency, automation, and tool longevity—critical for mechatronics applications in modern engineering and manufacturing processes. THANK YOU FOR LISTENING!!