As an alternative to milling with cooling lubricant, dry machining also offers a number of options. Materials such as steel and hardened steels, but also some castings, are suitable for this type of machining. In order to create a controlled dry machining environment, a number of factors must be taken into consideration. These include reduced heat generation (e.g. a smooth coating to reduce the friction factor) and heat dissipation (e.g. the right tool geometry to ensure efficient removal of heated chips). If the conditions are correct, a longer service life can often be achieved with dry machining than with wet machining because of the lower risk of thermal shock loads.

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As a manufacturer, we recommend dry machining with air cooling for our tools when working with hardened steel and almost all steels and castings. When milling aluminium, stainless steel, titanium and super alloys, on the other hand, we generally recommend the use of cooling lubricant.

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When the materials are machined, the mechanical forces produce extremely high temperatures. The majority of the heat is generated by the contact friction between the material surface and the cutting edge of the tool. These high temperatures can affect both the workpiece and the tool. Cooling lubricant is therefore used to counteract the temperature in the cutting zone and to reduce the thermal load on the milling cutter. Although the main purpose of the cooling lubricant is to lower temperatures, it also reduces frictional energy and flushes away any chips that are produced.

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The use of coolant is often essential for materials that tend to stick, for example certain aluminium and stainless steel alloys. The built-up edge that forms can sometimes lead to a distortion of the tool geometry and, in the worst case, can damage the cutting edge. However, despite the fact that machining with cooling lubricant is often very effective when working with metal, this method is still associated with considerable effort and related expenses. For example, choosing this method may involve investment, disposal and personnel costs.

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It is important to remember that the choice of cooling method is not only dependent on the material, the tool or the type of processing, but is also significantly influenced by the machine and the possible applications. Nevertheless, it simply wouldn’t make sense to use cooling lubricants for some materials, whereas others are naturally better suited to dry machining.

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Dry machining can be further categorised into two process variants: The tool is either cooled using compressed air or using a small amount of oil, which is dispersed in an oil/air mixture to form a film over the tool. This is referred to as minimum quantity lubrication (MQL). Wet machining, on the other hand, uses cooling lubricant to improve the milling process.

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Dry and wet machining is a controversial topic in the machining industry, with frequent discussions about how the machining of various materials can be improved using both methods. Although there are a number of factors to consider, the material properties are key. These properties determine which process should be used to ensure process-reliable manufacturing.

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Due to the change in temperature when milling with cooling lubricant, there is an additional risk of “thermal shock”. Thermal shock can occur when the cutting edge makes direct contact with the material (displacement of the cooling medium during the cutting process leads to high temperature absorption) followed by a subsequent interruption in the cutting process as soon as the cutting edge re-emerges from the workpiece. Thermal shock encourages the formation of cracks or chips on the tool, resulting in increased tool wear.

Although dry machining implies a lack of lubricant, a minimal number of drops of lubricant can be added in the form of an air/oil mixture. This differs from machining with cooling lubricant in that the tool is not fully immersed in the lubricant. The lubrication is delivered directly to the cutting edge at timed intervals during the machining process. This provides better lubrication than completely dry machining and reduces the frictional heat generated during the machining process. The advantage of both machining with minimum lubrication and wet machining with cooling lubricant is an improved surface quality during the finishing process.