Lubricants have always been used in mechanical processing – milling, drilling, sawing, punching. On one hand, in the form of cooling lubricants to dissipate heat, and on the other, oils to reduce friction and wear.

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And one way in which we can reduce the footprint of aluminium products is through dry machining. This means no longer using oil nor drinking water and lubricants in machining centers, with the aim of eliminating them throughout the machine area.

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Regardless of the approach you take when considering this option for your processes, you need to realize that doing away with coolants and lubricants in machining is an important step toward sustainability.

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In manufacturing plants, we can start by questioning the resource requirements of the various processes, the type and origin of the operating materials used, their impact on the environment and their recyclability. The avoidance of operating materials is a great step toward sustainability.

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CADEM CAPSturn CNC lathe programming software automatically determines the cutting feed rate based on the surface finish required and the tool’s nose radius.

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In a civilization that depends on machines, materials that lubricate moving parts have been considered essential. People have been using lubricants for thousands of years to improve production processes where friction causes wear. We started with prehistoric lubricants such as sludge, liquids from tree trunks and crushed reed, or wood and stones for the construction of buildings. We then moved to animal fats, fatty and oily substances from animal and vegetable oils, and whale oils.

Aluminium is the metal of the future with unique properties and endless application and design possibilities. But it still has a carbon footprint, like every other material, and when you fabricate the metal, the footprint grows. Now we can reduce this footprint with dry machining.

Aluminium profiles are traditionally machined in mechanical centers using CNC machines with cooling lubricants and lubricating oils in a minimum quantity lubrication system. Some companies machine their semi-finished aluminium products partially in a dry state, but there aren’t many.

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In our machining centers, we have decided to carry out milling without cooling lubricants and oils, and other machining steps will follow. We call this dry machining. The key is in the tools: special geometry for chip removal and tailor-made material selection are required.

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This nose radius chart shows the Rmax in microns for various combinations of nose radius and feed rate. These are theoretical values, and the actual finish that you get will depend on the tool wear, the quality of the machine, vibrations, etc. These values are however a good starting point.

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The problem is that petroleum-based lubricants pollute the environment and water directly and indirectly through the production, processing and emissions of the substances.

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Transitioning to dry machining is not simple, but it is attainable. Yes, there are issues, for instance with complex machining processes where realization without lubrication is demanding. Both thread cutting and deep blind holes drilling are not yet feasible without oil.

The nose radius of the insert has a direct effect on the surface finish of the part in turning. Turning actually forms a helical groove on the part – a thread. The depth of the groove is the roughness height. The roughness height (Rmax) is directly proportional to the square of the feed rate, and inversely proportional to the nose radius of the tool. You can actually use a quick reference nose radius chart to determine the feed rate that you must use to get a specified surface finish for any nose radius.

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Aluminium is a key building block for a more climate-friendly circular economy. Nevertheless, we are also aware of the challenges involved in making the entire value chain of the light metal more sustainable. And we need to be aware of these challenges, because the continuous reduction of the footprint of aluminium production and aluminium products is an ethical responsibility.

To improve the surface finish you can either reduce the feed rate or increase the nose radius. Halving the feed rate improves the surface finish four times (reduces the Rmax value by 75 %). Doubling the nose radius improves the surface finish twice (reduces the Rmax value by 50 %). You can use the insert nose radius chart above to quickly decide the feedrate obtainable.