The Design and Implementation of Fan Chips as Cooling for Milling Process on Aluminum Alloy 5086 to Increase Tool Life

Abstract

In the metal machining process, especially in the milling process, the parameters that affect the quality milling process results are cooling media because it affects the tool life used. This paper aims to determine the performance of using fan chips as the coolant in the dry milling process area. The method used is the computational fluid dynamic (CFD) method and the experimental milling process on a workpiece made from aluminum alloy 5086. In experimental testing using a variation of the milling machine spindle rotation. The simulation test results on the fluid flow character on fan chips with a protector producing a central character with a small area. In contrast, fan chips without a protector make a central character with a broader area. The wind speed data in simulation testing and experimental testing produced the same trend graph. The results of the performance of fan chips after experimented with variations in spindle rotation, cooling process on area occurs when the motor spindle rotates above 1120 Rpm on the fan chips with a protector, and the engine spindle rotates above 770 Rpm on the fan chips without a protector. The effect of fan chips on tool life affects increasing tool life by 8 minutes on installing fan chips with a protector and increasing tool life by 12 minutes on installing fan chips without a protector.

Utilization of Minimum Quantity Lubrication (MQL) Chip Fan on SS304 During Milling Process to Increase Carbide Tool Life

“…The temperature decrements are almost halves (around 73 to 113°C, or around ~40%) for the finishing process and more than half (around 47 -57%) for roughing process. This evidence showed that forced convection from the MQL Chip fan made a huge impact on the cooling processes [30].…”

Analisis Bentuk dan Jumlah Bilah pada Fan Chip Pendingin Portable untuk Proses Drilling Logam dengan Flow Simulation

“…Pada gambar 3 Menunjukkan hasil simulasi CFD bilah model 2 dengan jumlah 3 bilah fan chip portable untuk pendinginan proses pengeboran logam, dimana ditunjukkan pada hasil simulasi kecepatan dan temperature udara, dimana nilai maksimimum temperature udara sebesar 30,19 O C dan nilai minimum temperature udara sebesar 29,87 O C, minimum temperatur sebagai pendingin untuk udara dingin fan chip yang ditiupkan pada proses pendinginan tool [15]. Pada tabel 3 dan tabel 4, menunjukkan hasil yang berbeda dari setiap desain fan chip.…”