Abstract
The application of emulsion for combined heat extraction and lubrication requires continuous monitoring of quality of the emulsion to sustain the desired machining environment. To sustain a controlled machining environment, it is necessary to adopt an effectively lubricated tool–work interface. As a result, the study of the machining process using a limited amount of lubricant/coolant (Minimum Quantity Lubrication) is highly appropriate. The aim of this research is to develop a Computational Fluid Dynamics (CFD) model to duplicate the atomization (mist formation) in MQL milling. Air pressure and mass flow rate were considered as the process parameters. Discrete Phase Model (DPM) was used to simulate the atomization because the mass flow rate of the oil is very low and also it acts as a discrete medium in air. The diameter of the droplet and velocity of the jet were acquired at various input conditions for achieving the optimal values of oil mass flow rate and air pressure respectively. It is seen that medium size (around 10.2 µm) of droplet plays a significant role in improved performance by the way of reduction in cutting force and surface roughness in MQL milling of SS304.
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