EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

Wan Norsyazila Jailani,Mohammad Yeakub Ali,Muhammad Hasibul Hasan,Mohamed Rahman,Asfana Banu

doi:10.31436/iiumej.v18i1.638

Wan Norsyazila Jailani, Mohammad Yeakub Ali + Show 3 more

Open Access

https://doi.org/10.31436/iiumej.v18i1.638

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Abstract

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

Highlights

The increasing demands for miniaturized products, especially in the biomedical, electronics, and aerospace industries, have obliged manufacturers to fabricate complex micro-parts with high accuracy
The micropatterning method can be conducted by several micromachining processes such as electron beam etching, soft lithography, laser micromachining, micromilling, etc
The objective of this paper is to investigate and compare surface roughness with the presence of minimum quantity of lubrication (MQL) and dry cutting in micromilling of aluminum alloy 1100

Summary

Introduction

The increasing demands for miniaturized products, especially in the biomedical, electronics, and aerospace industries, have obliged manufacturers to fabricate complex micro-parts with high accuracy. One of the fast developing microfabrication methods is micropatterning, which has a broad application in cell biology and biodegradable implantable medical devices. The micropatterning method can be conducted by several micromachining processes such as electron beam etching, soft lithography, laser micromachining, micromilling, etc. Micromilling is one of the flexible mechanical micromachining processes that are capable for producing three dimensional (3D) miniaturized parts. It is characterized by the mechanical interaction between a sharp edged microtool and a workpiece material. Micromilling is similar to macro milling except for the tool size it employs [1,2,3,4,5,6]

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