Comparative Economic Analysis and Investigation of Micro Lubrication Over Conventional Cooling in Manufacturing

Abstract

Cutting fluid is a major concern in conventional cooling methods because of its high cost, effects on operator health, and environmental consequences. Microlubrication (MQL) is a better cooling method than traditional cooling. MQL can be used for machines with a high metal removal rate, such as those used in metal turning, milling, drilling, and boring. MQL has a lower lubrication consumption, a higher cooling rate, and a cleaner production than do conventional flooded lubrication. This study performed a cost-benefit analysis to compare MQL with conventional flood cooling methods. For both traditional flood cooling at 35 L/min and MQL cooling at 50 mL/h, face and slot milling techniques with constant machining settings were used. The quantity of components that must be produced to recoup the fixed and variable costs of MQL and conventional cooling were calculated by performing a breakeven point (BEP) analysis. The MQL methodology used 20% fewer components to recoup all expenses compared with conventional cooling. The findings indicated that MQL is more economical than traditional cooling. Moreover, the BEP for both cooling systems exhibited variances, and the BEP can be reached sooner for MQL than flood cooling lubricant.