This paper presents a two-dimensional steady-state incompressible analysis for the minimum quantity of lubricant flow in milling operations using a computational fluid dynamics (CFD) approach. The analysis of flow and heat transfer in a four-teeth milling cutter operation was undertaken. The domain of the rotating cutter along with the spray nozzle is defined. Operating cutting and boundary conditions are taken from the literature. A steady-state, pressure-based, planar analysis was performed with a viscous, realizable k-ε model. A mixture of oils and air were sprayed on the tool, which is considered to be rotating and is at a temperature near the melting temperature of the workpiece. Flow fields are obtained from the study. The vector plot of the flow field shows that the flow is not evenly distributed over the cutter surface, as well as the uneven distribution of the lubricant in the direction of the cutter rotation. It can be seen that the cutting fluid has not completely penetrated the tool edges. The turbulence created by the cutter rotation in the proximity of the tool throws oil drops out of the cutting zone. The nozzle position in relation to the feed direction is very important in order to obtain the optimum effect of the MQL flow.
This study is focused to determine the optimum operating parameters for the end milling process of AA6061T6 under wet cooling conditions. A central composite design of response surface methodology is used to develop an effective analytical model for surface roughness. The primary cutting parameters, namely, speed, feed rate and depth of cut, are considered in this study. Surface roughness is measured using a perthometer. The adequacy of the model is tested using ANOVA at 95% confidence level. Significant parameters are identified in terms of the cutting parameters. The obtained results show that the most significant parameters for the machining of the mentioned alloy are feed rate and depth of cut. The resultant model is then tested for optimization using a genetic algorithm.
In manufacturing, a great challenge is currently being faced in the competitive marketing place due to the manufacturing environment, low costs, the aim to achieve high rates of productivity and also the demand for high quality from customers. Aluminum alloys are being competitively used in current industries, especially in the automotive and aeronautics sector. This study is for experimental investigation of minimum quantity lubricant (MQL) for the end milling machining characteristics regarding tool wear during the machining of aluminum alloy 6061-T6. Process parameters including the cutting speed, depth of cut and feed rate are selected for study to develop a model of process optimization based on the response surface method. This experiment was conducted based on the central composite design method. Three types of tools are used in this experiment, namely, high speed steel, coated and uncoated carbide tools. The encouraging results include a significant reduction in the tool wear rate with MQL mainly through the reduction in the cutting zone temperature and a favorable change in the chip-tool and work-tool interaction. It is concluded that the MQL technique leads to economic benefits in terms of reduced lubricant costs and better machinability.
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