Shielding Nozzle Design and Analysis for Atomization-Based Cutting Fluid Systems in Micromachining

2015 ◽  
Vol 3 (2) ◽  
Author(s):  
Andressa Lunardelli ◽  
John E. Wentz ◽  
John P. Abraham ◽  
Brian D. Plourde
Keyword(s):  
Fluid Dynamic ◽  
Continuous Phase ◽  
Computational Fluid Dynamic Model ◽  
Parameter Analysis ◽  
Cutting Fluid ◽  
Nozzle Design ◽  
Fluid Systems ◽  
Cutting Surface ◽  
Droplet Tracking ◽  
Cooling And Lubrication

Atomization-based cutting fluid systems (ACFs) are increasingly being used in micromachining applications to provide cooling and lubrication to the tool–chip interface. In this research, a shielding nozzle design is presented. A computational fluid dynamic model is developed to perform parameter analysis of the design. The numerical simulations were accomplished using the Eulerian approach to the continuous phase and a Lagrangian approach for droplet tracking. Based on the results of the simulations it is determined that the shielding nozzle is effective at providing droplets to the cutting surface at an appropriate speed and size to create a lubricating microfilm.

Integration of Computational Fluid Dynamics and Experimentation in Undergraduate Fluid Mechanics

2006 ◽  
Author(s):  
Amir Jokar
Keyword(s):  
Fluid Mechanics ◽  
Numerical Solutions ◽  
Fluid Dynamic ◽  
Deep Understanding ◽  
Systems Design ◽  
Teaching Model ◽  
Engineering Curriculum ◽  
General Terms ◽  
Fluid Systems ◽  
Hands On

A combination of computational and experimental analyses with the conventional lectures and problem-solving in a fundamental course such as fluid mechanics can enhance students' learning enormously. This teaching model has been examined within the mechanical engineering curriculum at WSU Vancouver, and successful results have been obtained thus far. The goal in this course was first to seed concepts and theorems of fluid mechanics in general terms, followed by numerical solutions and hands-on experimentation on selective subjects. This would allow the students to gain a deep understanding of the contents within the course timeframe. For selective fluid problems with more complications, such as the flow in the entrance region of a pipe, a computational fluid dynamic (CFD) software known as FlowLab was used to obtain numerical solutions. The assigned computational projects could open the eyes of students to the world of CFD analysis in thermal/fluid systems design. The results of the numerical analysis were then compared to the theoretical and experimental results. For experimentation, the students were divided into groups to design experimental procedures, conduct experiments, collect and interpret data, and report the results in an appropriate format. The selective experiments were relevant to the course topics including Burdon pressure gauges, manometers, flow-rate measurements, pipe flow, and flow around immersed bodies in a water tunnel. The present study addresses the details, results, and advantages of such a multi-dimensional and more interactive learning model.

scholarly journals Energy Efficient Cutting Fluid Supply: The Impact of Nozzle Design

Procedia CIRP ◽  
2017 ◽  
Vol 61 ◽  
pp. 564-569 ◽  
Author(s):  
Nadine Madanchi ◽  
Marius Winter ◽  
Sebastian Thiede ◽  
Christoph Herrmann
Keyword(s):  
Energy Efficient ◽  
Cutting Fluid ◽  
Nozzle Design ◽  
Fluid Supply ◽  
The Impact

scholarly journals Pengaruh Kekasaran Permukaan terhadap Performa Slider Bearing Bertekstur dengan Menggunakan Pendekatan CFD

ROTASI ◽  
2019 ◽  
Vol 21 (1) ◽  
pp. 56
Author(s):  
Mohammad Tauviqirrahman ◽  
Mufti M. Suryaman ◽  
Muchammad Muchammad
Keyword(s):  
Dynamic Model ◽  
Computational Fluid Dynamic ◽  
Fluid Dynamic ◽  
Computational Fluid Dynamic Model ◽  
Slider Bearing ◽  
Multi Phase

Dalam teori pelumasan klasik hidrodinamika, asumsi permukaan kontak bearing yang benar-benar halus sering kali digunakan. Meskipun demikian, telah dibuktikan bahwa asumsi tersebut tidak realistis dikarenakan pada umumnya, tidak ada permukaan bearing yang benar-benar halus. Tulisan ini membahas pengaruh kekasaran permukaan terhadap performa slider bearing bertektur dengan menggunakan pendekatan CFD (computational fluid dynamic). Model kavitasi multi-phase digunakan untuk memodelkan fenomena kavitasi yang lebih riil. Performa slider bearing dengan tingkat kekasaran permukaan tertentu dibandingkan dengan slider bearing halus dengan menvariasikan kondisi inersia. Berdasarkan hasil simulasi, ditemukan bahwa tekanan hidrodinamik dan daya dukung beban berkurang dengan bertambahnya kekasaran permukaan. Selain itu, jika bearing dirancang agar memiliki kondisi inersia yang rendah, daya dukung beban akan menjadi lebih besar.

Characterization of Fluid Film Produced by an Atomization–Based Cutting Fluid (ACF) Spray System During Machining

2013 ◽  
Author(s):  
Alexander C. Hoyne ◽  
Chandra Nath ◽  
Shiv G. Kapoor
Keyword(s):  
Flow Characteristics ◽  
Fluid Film ◽  
Cutting Fluid ◽  
Spray Parameters ◽  
Film Model ◽  
Thin Fluid ◽  
Spray System ◽  
Thin Fluid Film ◽  
Film Development ◽  
Cooling And Lubrication

The atomization–based cutting fluid (ACF) spray system has recently been proposed as a cooling and lubrication solution for machining hard to machine materials (e.g. titanium alloys). On the tool rake face, the ACF spray system forms a thin film from cutting fluid that penetrates into the tool–chip interface to improve tool life. The objective of this work is to characterize this thin fluid film in terms of thickness and velocity for sets of ACF spray parameters. ACF spray experiments are performed by varying impingement angle in order to observe the nature of the spreading film, and to determine the film thickness at different locations after impingement of the droplets. It is observed that the film spreads radially outward producing three fluid film development zones (i.e. impingement, steady, unsteady). The steady zone is found to be between 3 and 7 mm from the focus (impingement point) of the ACF spray for the set of parameters investigated. An analytical 3D thin fluid film model for the ACF spray system has also been developed based on the equations for continuity of mass and momentum. The model requires a unique treatment of the cross–film velocity profile, droplet impingement and pressure distributions, as well as a strong gas–liquid shear interaction. The thickness profiles predicted by the analytical film model have been validated. Moreover, the model predictions of film velocity and chip flow characteristics during a titanium turning experiment reveal that the fluid film can easily penetrate into the entire tool–chip interface with the use of the ACF spray system.

Cutting Mechanism Study on Technology in Near-Dry Deep-Hole Drilling

2010 ◽  
Vol 455 ◽  
pp. 251-256
Author(s):  
Peng Hai ◽  
H.X. Wei
Keyword(s):  
Cutting Fluid ◽  
Hole Drilling ◽  
Deep Hole ◽  
Mechanism Study ◽  
Cutting Mechanism ◽  
Dry Cutting ◽  
Two Phase ◽  
Deep Hole Drilling ◽  
Mathematical Mode ◽  
Cooling And Lubrication

Near-dry deep hole processing technology is a kind of technology which dry cutting technology is applied to deep hole processing to save energy and decrease environmental pollution. In this paper, the structure and work principle of near-dry deep-hole drilling system were introduced and the cutting mechanism of near-dry deep-hole drilling was analyzed which include the mechanism of cutting fluid atomization and flow, the mechanism of atomized cutting fluid cool and lubricate, and the mechanism of separating chips into short pieces and discharge chips by air stream, etc. The mathematical mode of gas-liquid two-phase flow of atomized cutting fluid in drilling shaft and the cooling and lubrication mechanism of the capillary in cutting zone were introduced. It is found that near-dry deep hole processing has better cooling and lubrication effect through experiments.

scholarly journals A Numerical Model of the Onset of Stall Flutter in Cascades

1995 ◽  
Author(s):  
William S. Clark ◽  
Kenneth C. Hall
Keyword(s):  
Unsteady Flow ◽  
Stokes Equations ◽  
Fluid Dynamic ◽  
Computational Fluid Dynamic Model ◽  
Navier Stokes ◽  
Aeroelastic Stability ◽  
Blade Vibration ◽  
Navier Stokes Equations ◽  
The Mean ◽  
Stall Flutter

In this paper, we present a computational fluid dynamic model of the unsteady flow associated with the onset of stall flutter in turbomachinery cascades. The unsteady flow is modeled using the laminar Navier-Stokes equations. We assume that the unsteadiness in the flow is a small harmonic disturbance about the mean or steady flow. Therefore, the unsteady flow is governed by a small-disturbance form of the Navier-Stokes equations. These linear variable coefficient equations are discretized on a deforming computational grid and solved efficiently using a multiple-grid Lax-Wendroff scheme. A number of numerical examples are presented which demonstrate the destabilizing influence of viscosity on the aeroelastic stability of airfoils in cascade, especially for torsional modes of blade vibration.

Graphene Oxide Colloidal Suspensions as Cutting Fluids for Micromachining: Part 1 — Fabrication and Performance Evaluation

2015 ◽  
Author(s):  
Bryan Chu ◽  
Eklavya Singh ◽  
Johnson Samuel ◽  
Nikhil Koratkar
Keyword(s):  
Graphene Oxide ◽  
Cutting Temperature ◽  
Colloidal Suspensions ◽  
Cutting Fluid ◽  
Droplet Spreading ◽  
Bulk Fluid ◽  
Graphene Layers ◽  
Lubrication Performance ◽  
Cooling And Lubrication ◽  
Lateral Length

This paper is aimed at investigating the effects of graphene oxide platelet (GOP) geometry (i.e., lateral size and thickness) and oxygen functionalization on the cooling and lubrication performance of GOP colloidal suspensions. The techniques of thermal reduction and ultrasonic exfoliation were used to manufacture three different types of GOPs. For each of these three types of GOPs, colloidal solutions with GOP concentrations varying between 0.1–1 wt% were evaluated for their dynamic viscosity, thermal conductivity and micromachining performance. The ultrasonically-exfoliated GOPs (with 2–3 graphene layers and lowest in-solution characteristic lateral length of 120 nm) appear to be the most favorable for micromachining applications. Even at the lowest concentration of 0.1 wt%, they are capable of providing a 51% reduction in the cutting temperature and a 25% reduction in the surface roughness value over that of the baseline semi-synthetic cutting fluid. For the thermally-reduced GOPs (with 4–8 graphene layers and in-solution characteristic lateral length of 562–2780 nm), a concentration of 0.2 wt% appears to be optimal. The findings suggest that the differences seen between the colloidal suspensions in terms of their droplet spreading, evaporation and the subsequent GOP film-formation characteristics may be better indicators of their machining performance, as opposed to their bulk fluid properties.

Characterization of Fluid Film Produced by an Atomization-Based Cutting Fluid Spray System During Machining

2013 ◽  
Vol 135 (5) ◽  
Author(s):  
Alexander C. Hoyne ◽  
Chandra Nath ◽  
Shiv G. Kapoor
Keyword(s):  
Stokes Equations ◽  
Flow Characteristics ◽  
Fluid Film ◽  
Cutting Fluid ◽  
Spray Parameters ◽  
Film Model ◽  
Thin Fluid ◽  
Spray System ◽  
Thin Fluid Film ◽  
Cooling And Lubrication

The atomization-based cutting fluid (ACF) spray system has recently been proposed as a cooling and lubrication solution for machining hard to machine materials (e.g., titanium alloys). On the tool rake face, the ACF spray system forms a thin film from cutting fluid that penetrates into the tool–chip interface to improve tool life. The objective of this work is to characterize this thin fluid film in terms of thickness and velocity for a set of ACF spray parameters. ACF spray experiments are performed by varying impingement angle to observe the nature of the spreading film and to determine the film thickness at different locations after impingement of the droplets. It is observed that the film spreads radially outward producing three fluid film development zones (i.e., impingement, steady, and unsteady). The steady zone is found to be between 3 and 7 mm from the focus (impingement point) of the ACF spray for the set of parameters investigated. An analytical 3D thin fluid film model for the ACF spray system has also been developed based on the Navier–Stokes equations for mass and momentum. The model requires a unique treatment of the cross-film velocity profile, droplet impingement, and pressure distributions, as well as a strong gas–liquid shear interaction. The thickness profiles predicted by the analytical film model have been validated. Moreover, the model predictions of film velocity and chip flow characteristics during a titanium turning experiment reveal that the fluid film can easily penetrate into the entire tool–chip interface with the use of the ACF spray system.

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