Abstract: Additions of small but effective amounts of one or more of bismuth, indium, lead and/or tin to a silicon-containing aluminum casting alloy markedly improves the dry machinability of a casting made from the modified alloy. But dry machining of such castings is synergistically improved by the use of cutting tools with cutting surfaces coated with microcrystalline diamond or diamond-like carbon coatings. The use of such carbon-coated tools enables remarkable improvement in dry machinability even at reduced levels of the soft metal in the alloy.

Abstract: A nanofluid for dissipating friction and heat during machining includes a fluidic vehicle and a plurality of lubricious nanoparticles dispersed throughout the fluidic vehicle. A method for reducing material transfer during machining processes includes reducing a temperature of at least a portion of an article to be machined at least one of prior to machining, during machining, or combinations thereof.

Abstract: Additions of small but effective amounts of one or more of bismuth, indium, lead and/or tin to an aluminum casting alloy markedly improved the dry machinability of a casting made from the modified alloy. The added elements, which are softer and lower melting than the matrix alloy form as small globules dispersed in the microstructure of the aluminum casting. These globules do not adversely affect the strength or hardness of the casting but enable the casting to be machined without the use of a cooling and lubricating machining fluid.

Abstract: Additions of small but effective amounts of one or more of bismuth, indium, lead and/or tin to an aluminum casting alloy markedly improved the dry machinability of a casting made from the modified alloy. The added elements, which are softer and lower melting than the matrix alloy form as small globules in the microstructure of the aluminum casting. These globules do not adversely affect the strength or hardness of the casting but enable surfaces of the casting to be machined without the use of a cooling and lubricating machining fluid.

Abstract: Workpiece cutting tools, such as drills, are often provided with through holes that preferably extend from the cutting end of the tool along its length to the holding end. In accordance with this invention, such through holes of a cutting tool are filled with a lubricating oil-in a thermoplastic polymer matrix by injection or molding of the mixture into the holes. In the operation of the tool, the oil thus stored within the tool flows in the polymer matrix to the cutting site to reduce cutting power requirements and wear of the tool. Through the use of such cutting tools, the use of metal removal fluids can be eliminated and dry machining facilitated.