Material removal processing has been investigated both theoretically and experimentally to a certain extent. The demands for environmentally friendly processes impose new parameters such as the use of minimal quantity or even the complete omission of cutting fluids. Therefore, the related processes need to be newly studied in order to be optimized for specific cutting conditions. Cutting fluids are used in material removal processes mainly for lubrication, reduction of the temperature in the cutting region, and increase of tool life. However, cutting fluids are associated with skin and breathing problems of the machine operators. Furthermore, after their disposal and if, as in most cases, recycling is not possible, they may become polluting agents in soil and water when inappropriately handled. In this paper the case of hard cutting, a process that can be performed without the use of a cutting fluid, is investigated. A discussion on the technological parameters involved is given and experimental data are presented in order to point out the environmental as well as the economical benefits emerging from the use of such a technology.
