Abstract
Minimum Quantity Lubricants is a technique in supplying small quantity of lubricant into machining area which also part of green manufacturing approach that receive wide attention globally. The main driven of introducing MQL method was due to negative environmental impact which leads to safety and health issues of conventional coolant among workers especially in tool and mould industries. Besides, based on research findings, the MQL system has the capability for lubricating and cooling both work piece and cutting tool. In order to find the best solution for machining and also to enhance machining performance, first and foremost the MQL parameters must be controlled wisely as it has remarkable effects on lubricant coverage, droplets size and subsequently influence the machining performance. Nozzle angle, nozzle distance and MQL flow rate are the important parameters studied and surface roughness is the response parameter. Therefore, in this study, MQL optimum parameters were explored by minimizing surface roughness in end milling process using Taguchi L9 orthogonal method. Aluminum Alloy 6061-T6 was selected as work piece material. The results show that the best combination of MQL parameters in minimizing surface roughness was obtained at 30mm nozzle distance, 30 degree nozzle angle and 1.98 mL/min MQL flow rate. Hence, based on this optimal condition, three confirmation runs were conducted. The margin error is acceptable which less than 10% and within prediction interval. This results can work as a base line guidance for any experimental that employ MQL system.
Highlights
Metal cutting lubrication is crucial in metal removal process that relies on high intensity of shear deformation
Based on a 2D steady-state computational fluid dynamics (CFD) analysis done by Najiha et al[6], the minimum quantity lubricant (MQL) nozzle performance was achieved by the three nozzles arrangement instead of one nozzle arrangement and it works well for lubricating the rotating tool
It is clear that MQL parameters have remarkable effects to the machining performance
Summary
Metal cutting lubrication is crucial in metal removal process that relies on high intensity of shear deformation. Flooded cooling is the only option which can removes the heat and lubricating the machining area. Minimum quantity lubricant (MQL) approach has been explored since to overcome these issues. This is because based on study done by General Motor, the MQL particle size is less than 5μm which can be considered as fine mist compared to 10 μm particle size of flooded lubricant [2]. Based on a 2D steady-state computational fluid dynamics (CFD) analysis done by Najiha et al[6], the MQL nozzle performance was achieved by the three nozzles arrangement instead of one nozzle arrangement and it works well for lubricating the rotating tool. Erween et al [8] studied the effect of two different nozzle outlet diameter of 2.5mm and
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