E. Abba; A. Speidel; Z. Liao; D. Novovic; D. Axinte
Materials & Design 251 (2025) 113690
In manufacturing, cutting tools and component integrity are subjected to high-performance thresholds. The role
of cutting fluids is pivotal in mitigating heat generation and friction at the tool-workpiece interface. This study
explores the application of specifically designed, unconventional, and eco-friendly media, Deep-Eutectic Fluids
(DEFs), which provide optimized fluid delivery to the cutting zone, regulating lubrication and cooling, while
maintaining the surface integrity of the machined parts. To benchmark DEFs against traditional material removal
methods, including dry, and wet (emulsion-based, Hocut 3380) processes, grinding was selected due to its
thermal and lubrication demands. The results indicate that DEFs reduce the formation of severely deformed
layers by 47% in comparison to conventional water-based coolants exhibiting superior lubricity, yielding more
consistent deformation profiles and lower surface roughness. The generated residual stresses are closely com-
parable to those achieved using water-based metalworking fluids. This was substantiated by micromechanical
testing, revealing a coherent failure mechanism at the machined edges for both DEF and wet-cutting media,
significantly mitigating the adverse effects of dry machining. These findings highlight DEFs’ potential for
industrial-scale adoption as a sustainable alternative in material removal processes, underscoring their capability
to enhance process efficiency and environmental sustainability, or as an in-field portable cutting fluid.