Faculty Advisor

Mustapha S. Fofana

Faculty Advisor

Richard D. Sisson

Faculty Advisor

Yiming Rong


The purpose of this thesis is to investigate the correlation between the penetration force of cutting fluids and machining stability. General studies are made to understand the classification of cutting fluids based on their chemical compositions. It is summarized why the proper selection of cutting fluid for different machining processes is important. The role of cutting fluids in machining process is documented as well as other related issues such as delivery methods, storage, recycling, disposal and failure modes. The uniqueness of this thesis is that it constructs a new mathematical model that would help to explain and quantify the influence of the penetration force of cutting fluid on machining stability. The basic principles of milling process, especially for thin wall machining are reviewed for building the mathematical model. The governing equations of the mathematical model are derived and solved analytically. The derived solutions are used to construct the stability charts. The results show that there is a direct correlation between the machining stability and the changes of the penetration force of the cutting fluid. It is shown that the machining stability region is narrowed as the penetration force of the cutting fluid increases while other machining variables are assumed to be constant. This narrowness of the stability region is more obvious at spindle speed over 6000 rpm.


Worcester Polytechnic Institute

Degree Name



Manufacturing Engineering

Project Type


Date Accepted





Milling process, Stability regimes, Time delay, Cutting fluid