scholarly journals Development of a Low Cost Eco-Friendly Minimum Quantity Lubrication System for Machining Processes

2021 ◽  
Vol 8 ◽  
pp. 37-47
Author(s):  
Arunachalam Ramanathan ◽  
Sumaya Al Rumhi ◽  
Noor Al Hamimi ◽  
Shurooq Al Ajmi
Keyword(s):  
Quality Function Deployment ◽  
Cooling System ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Lower Surface ◽  
Machining Processes ◽  
Decision Matrix ◽  
Minimum Quantity ◽  
Lathe Machine ◽  
Mql System

Recently all environmental worries are calling for reducing the usage of fluids in machining operations. One of the promising solutions that appeared lately is minimum quantity lubrication (MQL). This research aimed to develop an eco-friendly cooling system for a lathe machine and assess its performance. After considering the customer needs, the needs were translated into engineering specifications in the conceptual design phase, and then the quality function deployment was developed. Three concepts were generated and evaluated considering the selection criteria, and a final concept was selected using the decision matrix method. Following this, a detailed design and fabrication of the subsystems such as the oil tank and a structure accommodate all the components. The developed system was tested on six different workpiece samples to compare the MQL system with the conventional one. In general, the MQL system resulted in lower surface roughness values as well as lower tool wear.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

Application of the auxiliary wheel cleaning jet in the plunge cylindrical grinding with Minimum Quantity Lubrication technique under various flow rates

2018 ◽  
Vol 233 (4) ◽  
pp. 1144-1156 ◽  
Author(s):  
Eduardo C Bianchi ◽  
Rafael L Rodriguez ◽  
Rodolfo A Hildebrandt ◽  
José C Lopes ◽  
Hamilton J de Mello ◽  
...  
Keyword(s):  
Environmental Sustainability ◽  
Substantial Reduction ◽  
Minimum Quantity Lubrication ◽  
Economic Benefits ◽  
Grinding Wheel ◽  
Machining Processes ◽  
Potential Health ◽  
Abrasive Wheel ◽  
Flow Rates ◽  
Minimum Quantity

Minimum Quantity Lubrication is an alternative technique to conventional techniques that are related to environmental sustainability and economic benefits. This technique promotes the substantial reduction of the amount of coolant employed in machining processes, representing a mitigation of risks to people’s health that are involved with the process. On the other hand, it has been reported in the literature that some problems of using the Minimum Quantity Lubrication technique can impair the grinding efficiency. One of these problems is associated with wheel clogging phenomenon, which is caused by inefficient chip removal from the cutting zone as well as from mixture of metal dust and oil accumulated on the wheel surface during grinding. If chips lodge inside the pores of the grinding wheel as machining progresses, they will adversely affect dimensional and geometric quality of final product. Also, this will require more frequent dressing. A solution for this problem can be an effective cleaning system of the abrasive wheel during grinding with the traditional Minimum Quantity Lubrication technique Assisted with Wheel Cleaning Jet. In this context and aiming to explore the various potential health, environmental and economic benefits that have been widely reported in the literature about the use of Minimum Quantity Lubrication technique in grinding, this study presents an application of the Minimum Quantity Lubrication technique at flow rates (30, 60 and 120 mL/h) and assisted with wheel cleaning jet (Minimum Quantity Lubrication + Assisted with Wheel Cleaning Jet) in plunge grinding of a hardened steel with an aluminum oxide wheel. Experiments were also carried out with traditional Minimum Quantity Lubrication (without wheel cleaning) and with the conventional coolant techniques for comparison. The output variables were geometrical errors (surface roughness and roundness) of the workpiece, diametric wheel wear, acoustic emission, vibration and tangential cutting force. Results showed that Minimum Quantity Lubrication + Assisted with Wheel Cleaning Jet (with wheel cleaning jet) not only outperformed the traditional Minimum Quantity Lubrication technique in all the parameters analyzed, but in some cases it proved to be compatible with the conventional coolant technique under the conditions investigated. Also, most of values of the output parameters tested decreased with increase in flow rate.

Experimental Investigation on Turning of Monel K500 Alloy Using Nano Graphene Cutting Fluid Under Minimum Quantity Lubrication

2019 ◽  
Author(s):  
Arul Kulandaivel ◽  
Senthil Kumar Santhanam
Keyword(s):  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
High Strength ◽  
High Heat ◽  
Water Soluble ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Turning Operation ◽  
Minimum Quantity

Abstract Turning operation is one of the most commonly used machining processes. However, turning of high strength materials involves high heat generation which, in turn, results in undesirable characteristics such as increased tool wear, irregular chip formation, minor variations in physical properties etc. In order to overcome these, synthetic coolants are used and supplied in excess quantities (flood type). The handling and disposal of excess coolants are tedious and relatively expensive. In this proposed work, Water Soluble Cutting Oil suspended with nanoparticles (Graphene) is used in comparatively less quantities using Minimum quantity lubrication (MQL) method to improve the quality of machining. The testing was done on Turning operation of Monel K500 considering the various parameters such as the cutting speed, feed and depth of cut for obtaining a surface roughness of 0.462μm and cutting tool temperature of 55°C for MQL-GO (Graphene oxide) process.

scholarly journals Study on Tool Deterioration in Machining with Minimum Quantity Lubrication (MQL) Condition

Teknik ◽  
2020 ◽  
Vol 41 (3) ◽  
pp. 261-268
Author(s):  
Rika Dwi Hidayatul Qoryah ◽  
Allen Luviandy ◽  
Mahros Darsin
Keyword(s):  
Cutting Tool ◽  
Minimum Quantity Lubrication ◽  
Depth Of Cut ◽  
Side View ◽  
Anova Analysis ◽  
Cooling Fluid ◽  
Minimum Quantity ◽  
Application Methods ◽  
Four Levels ◽  
Mql System

This study aims to observe the tool deterioration following application of minimum quantity lubrication method (MQL). The designed MQL system is completed with an Arduino controller system which was able to be either manually-controlled or automatically-controlled. The tool used in this study is DCMT 11 insert type. The Taguchi method using the Orthogonal Array L9 design was used to compile the design of experiments with variations in depth of cut, coolant composition, and cooling fluid application methods. Each variable consists of three levels. Tool deterioration evaluated by observing it under an optic microscope from three sides of the tool. There are four levels of tool deterioration. The value of tool deterioration of each tool is the accumulation of each side view. ANOVA analysis found that depth of cut, cutting tool composition and method of applying coolant influence tool deterioration in percentage by 32.69%, 17.30 % and 12.82% respectively. Moreover, the minimum tool deterioration would be achieved when using the parameter combination of depth of cut of 1.6 mm; mixture composition of 3:7; and using the temperature-controlled MQL. 

Selection of Minimum Quantity Lubrication (MQL) Parameters in Milling of Ti-6Al-4V

2012 ◽  
Vol 426 ◽  
pp. 139-142 ◽  
Author(s):  
Zhi Qiang Liu ◽  
X.J. Cai ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Minimum Quantity ◽  
Nozzle Position ◽  
Mql System ◽  
End Milling Process ◽  
Selection Of

Different parameters of Minimum Quantity Lubrication (MQL) system, including air pressure, oil quantity, nozzle position, might have different influences on the cutting force and the cutting temperature. This paper presents an experiment of end-milling titanium alloy with MQL system. The objective of the experiment is to investigate the influences of MQL parameters in milling of Ti-6Al-4V. The results of experiment show that there are different effects on the cutting force and the cutting temperature with different MQL parameters, which will help to select different parameters in the end-milling process of Ti-6Al-4V.

The Impact of Cooling System on Surface Quality in Milling

2015 ◽  
Vol 809-810 ◽  
pp. 135-140 ◽  
Author(s):  
Bogdan Alexandru Chirita ◽  
Nicolae Catalin Tampu
Keyword(s):  
Heat Dissipation ◽  
Cooling System ◽  
Minimum Quantity Lubrication ◽  
Production Costs ◽  
Cutting Fluids ◽  
Cryogenic Machining ◽  
Machining Processes ◽  
Dry Cutting ◽  
Environment Quality ◽  
The Impact

In the last years there has been an increased demand to lower the impact of industrial activities on environment quality. Cutting fluids, among other products, are an important pollutant but they have often been associated with the need for a higher productivity of machining processes. Cutting fluids are a mean of reducing temperature in the cutting area, friction and tool wear but they also represent 7% to 17% of the production costs. Other problems raised by cutting fluids are: microorganism infestation, which can cause pulmonary and dermatological diseases and poor lubrication or corrosion caused by some of the chemicals. Dry cutting is regarded as the cleanest cooling method, but it has a reduced heat dissipation efficiency and practically there is no lubrication. Other relatively new green solutions concern the use of minimum quantity lubrication (MQL) and cryogenic machining.

scholarly journals Minimum Quantity Lubrication (MQL) and its Effect on Tool Wear During Miniature Drilling :an Experimental Study

2016 ◽  
Vol 1 (2) ◽  
pp. 65-70
Author(s):  
Norsalawani Binti Mohamad ◽  
Rubina Bahar
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Minimum Quantity Lubrication ◽  
Limiting Factors ◽  
Work Piece ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Tool Condition ◽  
Overall Performance

Miniature drilling is widely used in industries including electronics and reconstructive surgeries to create small sized holes. Chip removal and effective supply of coolant are the two limiting factors that make the process more complex compared to other meso scale machining processes and also contribute to the tool wear. The tool wear in the process is mainly caused by the interaction, motion and chip production between the tool and work piece. Uniform supply of coolant must be ensured to reach the drilled cavity to keep the tool wear to a minimal level. This study includes experimental investigation of the tool condition after applying Minimum Quantity Lubrication (MQL) system as a greener approach as the name indicates. The tool condition with MQL has also been compared with dry and flood cooling. Two different types of drill bit materials (High Speed Steel and Carbide) have been tested under same experimental condition to drill through Aluminum Alloy 6061 and it has been found that overall performance in terms of tool condition after applying MQL was better compared to the other two methods. The overall wear propagation area was measured for both the conditions. It was seen, the wear propagation covered minimal area with MQL while for flood and dry condition wear was spread over a bigger area on flank. 

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