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Typical MQL setup 38
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Cutting fluids are required in huge amount in the modern machining methods. Cutting fluids are needed for providing lubrication as well as cooling the workpiece during machining. Cutting fluids are made of mineral oils and have many drawbacks including many health hazards and environment impact. Various other methods of cutting fluid delivery are b...
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... has many advantages like it increases tool life and surface finish [6][7][8][9][10][11][12][13] . A typical MQL involves use of high pressure liquid from 2 bar pressure to 5 bar pressure and lubricant in atomized form as shown in Fig 1. The atomized lubricant is in the range of microns and in combination with the high pressure air is able to penetrate the cutting zone effectively 3,14,15 . ...
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The cooling applications during machining has significant effects on the production
costs, surface quality, and the mechanical properties of the final product. In conventional flood
cooling, a large amount of continuous cooling fluid is usually used, and that increases the cost
of the product as well as the harmful effects on the environment and th...
Citations
... Cutting fluids are employed at the cutting zone to slow down the wear on the cutting tool and reduce the temperature, inturn increase the life of the tool. These cutting fluids contribute to occupational safety risks, environmental impact, and health hazards (Katna, Agrawal and Suhaib 2020). The initial alternative for making the manufacturing process sustainable was dry machining. ...
The material processing industry is anticipated to mitigate environmental degradation. The protocols established by the International Organisation for Standardisation were adhered to. As a result, it would be prudent to investigate the feasibility of minimizing the use of synthetic cutting fluids from the machining process. This study discusses an environmentally-friendly machining technique for turning nickel-based alloy Monel-500, which evaluates four different cooling conditions: dry machining, flood machining, Co-MQL (coconut oil), and Rb-MQL (Rice Bran Oil). These conditions were tested by experimenting with various machining parameters to investigate four aspects of the turning process: surface finish,cutting temperature, tool wear and chip morphology. Rice bran oil is considered eco-friendly compared to synthetic cutting fluids, and employing it in minimum quantity is economical and helps improve the machined workpiece’s surface finish. The investigation has been further extended by applying machine learning algorithms to predict surface roughness, utilising two logical regressions implemented in Python. Among the two machine learning approaches, the random forest regression technique has demonstrated superior results, achieving a prediction accuracy of 99.8%. Consequently, a decision tree has been developed using this regression model to predict the surface roughness. The structured analysis of the decision tree provides more accurate conclusions, offering flexibility in adjusting parameters and expanding options for operation. As a result, the decision tree approach enables the efficient utilisation of production resources and enhances production capacity by making informed choices about cooling methods during the turning process. Rb-MQL has performed better in all aspects than the other three cooling conditions. When comparing machining under dry conditions, flood cooling, Co-MQL, and Rb-MQL (rice bran oil) reduce the tooltip temperature by 39.5%,25.45 and 24.11%, respectively. Rb-MQL reduced surface roughness by 28.23%,43.59 and 60.49% in contrast with machining under dry, flood, and Co-MQL.
... However, the use of ultrasonic MQL can aid in achieving the desired droplet size and sustaining the mist velocity necessary for adequate transportation to the cutting zone. Using ultrasonic minimum quantity lubrication enhances surface polish and significantly extends the lifespan of tools [17,18]. The electrostatic MQL spraying apparatus has a single syringe pump, charge nozzle, and high-voltage electrodes as its standard configuration. ...
Minimum quantity lubrication (MQL) is a sustainable machining process in which oil and air are mixed to form a spray that can be directed to the cutting zone. MQL spray factors like droplet size and velocity and their effect on machining remain unclear, especially when employing diverse oils and operating settings. Mist formation factors determine how well spray droplets lubricate the targeted area during machining. Numerical and Experimental studies were conducted with different values for cutting fluid type, air pressure, and flow rate to establish the best possible combination to give the ideal droplet size and surface roughness. The study utilized three types of oils and varied air pressures to evaluate the cooling effectiveness of MQL spray during milling operations. Experimental droplet size and velocity measurements were obtained using ‘Phase Doppler Anemometry (PDA)’ and ‘Particle Image Velocimetry (PIV)’ techniques. A numerical model within ANSYS Fluent software, employing computational fluid dynamics (CFD), predicted spray flow properties and was validated using PIV data. Raising air pressure decreased droplet size while increasing velocity to achieve greater overall speed and enhanced lubrication in the cutting region. Changing the coolant flow rate or the compressed air pressure affected the Sauter mean diameter (SMD). The research showed that increasing air pressure from 1 bar to 3 bars reduced surface roughness by 55.40 percent and SMD by 24.58 percent for 120V oil. Among the three cutting oils tested, the 120V oil achieved the lowest surface roughness at 0.227µ under specific conditions: a flow rate of 150ml/hr, pressure of 3 bars, and SMD of 35.5 µm. These findings provide valuable insights into improving MQL efficiency for machining operations.
Nanoparticles, which are particles with dimensions on the nanoscale, have a wide range of applications across many different fields. Nanoparticles are used in many fields, such as electronics, medicine, cosmetics, manufacturing, and materials science. They have unique properties such as a high surface area-to-volume ratio, high reactivity, and the ability to interact with biological systems. In this chapter, the applications and effects of nanoparticles in conventional—Lathe, Grinding, Milling, and drilling processes—and unconventional machining processes—electro-chemical machining, electro-discharge, ultrasonic, abrasive waster-jet machining—processes are illustrated. Special applications of nanoparticles in medicine, agriculture, food, construction, biotechnology, and IC engines have also been discussed. The limitations of using nanoparticles in engineering applications have also been explained.
Cutting fluids are required for machining operations. However, the constituents of the mineral oil-based cutting fluids used in the industry have carcinogenic effects on the human and a negative impact on the environment. Non-edible vegetable oils can be a good potential to be used as a feasible alternative. A cutting fluid is formulated from non-edible vegetable oil using eco-friendly constituents and balancing the lipophilicity and hydrophilicity of the oil. The formulated cutting fluid and its concentrate was found to be stable for a long duration. Performance comparison was carried out with a conventional mineral oil-based cutting fluid and the results shows that the non-edible vegetable oil-based cutting fluid was able to reduce the cutting forces and surface roughness and also there was a significant reduction in tool wear. ANOVA results showed that the type of cutting fluid has a significant contribution on the surface roughness (69.15%) and tool wear (56.85%). The formulated cutting fluid has better performance and the results point positively toward promoting non-edible oil-based cutting fluid in machining.
This paper presents a new method of combining Minimum Quantity Lubricant (MQL) with ultrasonic assistance in deep hole drilling processes for difficult-to-cut materials, using internal coolant tools. A small amount of lubricant as 90 mL/h was provided directly into the cutting zone during deep drilling under ultrasonic vibrations exerted on the tool. A comparative experimental study was implemented for two
types of drilling processes: conventional drilling (CD) and ultrasonic-assisted drilling (UAD). For each set, three different methods of lubricant feeding methods were applied, including flooding, MQL, and MQL with graphene nanoparticles. A continuous drilling process using a through-hole drill bit (D = 5 mm, L = 8D) for AISI SUS 304 stainless steel was implemented to validate the effectiveness of the proposed approach. The results show that the approach proposed can overcome the bottleneck in deep drilling using MQL, providing a higher production rate, longer tool life, and better machining performance in
terms of cutting forces and processing ability. Using the newly proposed method, continuous drilling can be done in critical machining conditions, which are typically recommended by the tool manufacturers.The results are promising to expand to deep hole drilling of other hard-to-cut materials.
