Abstract
The purpose of this study aims at presenting a method formodelling machining processes considering MinimumQuantityLubrication (MQL) in a 2D and 3DFEMsimulation by using the example of machining tempered steel AISI 4140. All parameters required for the FEMsimulation are calculatedwithin the multiphase simulation code INSFLA and the formula for the heat conduction coefficient is derived. To consider the influence of phasetransformations of the fluid, separate experiments are performed. Furthermore, the frictioncoefficient is measured experimentally in dependence of the relative sliding velocity, contact pressureand temperature during machining with MQL as well as under dry conditions. The extended friction modelis used for the 2D and 3D models. MQLmachining experiments areperformed for the purpose of validating these models. The main focus of the experiments is layed on cutting temperatures, forces and phasetransformations on single workpieces.
Highlights
Minimum Quantity Lubrication (MQL) is a widely used machining technology in industry and research
As a mixture of wet and dry machining, the MQL technique combines the positive effects of both methods
It has been shown that the machining forces and temperatures are lower than in dry machining or flooded cooling
Summary
Minimum Quantity Lubrication (MQL) is a widely used machining technology in industry and research. The main machining processes, the MQL is applied to, are drilling [1], turning [2] or milling [3]. The influence of the process parameters like cutting speed, depth of cut, feed or nozzle position on temperature, surface roughness and machining forces in turning have been examined by Hadad et al [5]. It has been shown that the machining forces and temperatures are lower than in dry machining or flooded cooling. This causes a better tool chip interaction because of lower wear and better surface roughness. The nozzle position affects the supplied oil mist and the coating applied to the rake face and flank face. The nozzle position affects the supplied oil mist and the coating applied to the rake face and flank face. [6]
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