Utilization of Minimum Quantity Lubrication (MQL) Chip Fan on SS304 During Milling Process to Increase Carbide Tool Life

Abstract

Minimum quantity lubrication (MQL) is the most used recent method in the milling process that is economical and environmentally friendly. The MQL method can reduce the temperature during the milling process. The high temperature that occurs in the carbide tool will affect the tool’s life. The use of cooling fluid is a common method to reduce high temperatures. However, the remaining cooling fluid has an impact on the pollution of the environment. Therefore, in this study, a novel approach for a cooling system based on the combined MQL method and fan cooling device was introduced and called an MQL Chip fan. The effect of the MQL Chip fan on the temperature, tool life, and surface roughness was investigated. The Taylor equation was used to calculate tool life based on temperature data from an experimental investigation. Subsequently, the quality inspection was conducted by using a surface roughness tester. The spindle speed and depth of cut have proven to make a great impact on the peak temperature, but, there is an optimal point where spindle speed made a turbulence and the tool had a passive cooling system. The utilization of the MQL Chip fan has decreased temperature by more than half at a medium speed of 2241 rpm and made a high contribution for low-speed processing and only a slight contribution for high-speed processing. Based on Tool Life prediction, 3600 RPM with a 3 mm depth of cut has more efficient performance compared to 2241 rpm with the same depth of cut. The utilization of the MQL Chip fan contributes significantly to the roughness value; the Ra value decreased from 1.374 μm to 0.461 μm. It has been proven that the utilization of an MQL Chip fan in the milling process reduces temperature and also increases the tool life.