Effects of Ion-Shot Coolant System on Cutting of the Ferrous material with a Diamond Tool

A special coolant system called ‘ion-shot coolant system’ was developed for machining of the ferrous material with a diamond tool. It consists of ELID (Electrolytic In-process Dressing) liquid and nanometer size carbon particles. A series of micromachining experiments were conducted on high carbon chromium steel workpieces with single diamond tools and the results were compared with the conventional kerosene mist supply system. The ion-shot coolant system protected the tool from diffusion wear, produced improved surface quality, and discharged minute chips from the cutting interface and freshly
cut surface by electro-chemical adhesion process which produced electrostatic repel force. Preliminary study was conducted to understand the fundamental mechanism for above mentioned phenomena and hypothetical explanation were proposed.