Skip to main content
SpringerLink
Log in

Numerical and experimental optimizations of nozzle distance in minimum quantity lubrication (MQL) milling process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Minimum quantity lubrication (MQL) is the efficient and environmentally friendly technology, which is desirable to achieve sustainability during machining process. The nozzle distance has its significance in dominating the MQL spray and the related droplet transportation and penetration. In this paper, the nozzle distance has been optimized for MQL milling process through numerical and experimental methods. A two-way computational method has been employed to solve for the comprehensive flow field and particle trajectories, with the wall condition established on the spray impingement theory. The interactions of air flow rates and spindle rotational speeds on droplet penetration are investigated in details. The optimal ranges of nozzle distance setup obtained by simulation for different conditions were verified via slot milling tests, in which the nozzle distances were selected according to the key points obtained in the numerical process. The cutting force and surface roughness were recorded for the verification of adhesion ability and the related cutting performance. The comparison between numerical simulations and milling experiments has shown great consistency. This paper has achieved better understanding of the nozzle orientation setup and device development in MQL milling process, especially for external MQL. The theoretical basis and scientific instruction have been provided for the optimization of MQL operating parameters in industrial applications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Klocke F, Eisenblätter G (1997) Dry cutting. CIRP Ann 46:519–526. https://doi.org/10.1016/S0007-8506(07)60877-4

    Article  Google Scholar 

  2. Iskandar Y, Tendolkar A, Attia MH, Hendrick P, Damir A, Diakodimitris C (2014) Flow visualization and characterization for optimized MQL machining of composites. CIRP Ann 63:77–80. https://doi.org/10.1016/j.cirp.2014.03.078

    Article  Google Scholar 

  3. Leppert T (2012) Surface layer properties of AISI 316L steel when turning under dry and with minimum quantity lubrication conditions. Proc Inst Mech Eng B J Eng Manuf 226:617–631. https://doi.org/10.1177/0954405411429894

    Article  Google Scholar 

  4. Zhang S, Li JF, Wang YW (2012) Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions. J Clean Prod 32:81–87. https://doi.org/10.1016/j.jclepro.2012.03.014

    Article  Google Scholar 

  5. Bhowmick S, Alpas AT (2011) The role of diamond-like carbon coated drills on minimum quantity lubrication drilling of magnesium alloys. Surf Coat Technol 205:5302–5311

    Article  Google Scholar 

  6. Sanchez JA, Pombo I, Alberdi R, Izquierdo B, Ortega N, Plaza S, Martinez-Toledano J (2010) Machining evaluation of a hybrid MQL-CO2 grinding technology. J Clean Prod 18:1840–1849. https://doi.org/10.1016/j.jclepro.2010.07.002

    Article  Google Scholar 

  7. Lawal SA, Choudhury IA, Nukman Y (2013) A critical assessment of lubrication techniques in machining processes: a case for minimum quantity lubrication using vegetable oil-based lubricant. J Clean Prod 41:210–221

    Article  Google Scholar 

  8. Tawakoli T, Hadad MJ, Sadeghi MH (2010) Influence of oil mist parameters on minimum quantity lubrication–MQL grinding process. Int J Mach Tools Manuf 50:521–531. https://doi.org/10.1016/j.ijmachtools.2010.03.005

    Article  Google Scholar 

  9. Mulyadi IH, Mativenga PT (2014) Random or intuitive nozzle position in high-speed milling using minimum quantity lubricant. Proc Inst Mech Eng B J Eng Manuf 228:21–30. https://doi.org/10.1177/0954405413495536

    Article  Google Scholar 

  10. Hadad M, Sadeghi B (2013) Minimum quantity lubrication-MQL turning of AISI 4140 steel alloy. J Clean Prod 54:332–343. https://doi.org/10.1016/j.jclepro.2013.05.011

    Article  Google Scholar 

  11. Masoudi S, Vafadar A, Hadad M, Jafarian F (2017) Experimental investigation into the effects of nozzle position, workpiece hardness, and tool type in MQL turning of AISI 1045 steel. Mater Manuf Process 33:1–9. https://doi.org/10.1080/10426914.2017.1401716

    Google Scholar 

  12. Yan L, Yuan S, Liu Q (2012) Influence of minimum quantity lubrication parameters on tool wear and surface roughness in milling of forged steel. Chin J Mech Eng 25:419–429. https://doi.org/10.3901/CJME.2012.03.419

    Article  Google Scholar 

  13. Obikawa T, Asano Y, Kamata Y (2009) Computer fluid dynamics analysis for efficient spraying of oil mist in finish-turning of Inconel 718. Int J Mach Tools Manuf 49:971–978. https://doi.org/10.1016/j.ijmachtools.2009.06.002

    Article  Google Scholar 

  14. Pervaiz S, Deiab I, Rashid A, Nicolescu M (2017) Minimal quantity cooling lubrication in turning of Ti6Al4V: influence on surface roughness, cutting force and tool wear. Proc Inst Mech Eng B J Eng Manuf 231:1542–1558. https://doi.org/10.1177/0954405415599946

    Article  Google Scholar 

  15. Bai C, Gosman AD (1995) Development of methodology for spray impingement simulation[R].SAE Technical Paper

  16. Stow CD, Hadfield MG (1981) An experimental investigation of fluid flow resulting from the impact of a water drop with an unyielding dry surface. Proc R Soc Lond A 373:419–441. https://doi.org/10.1098/rspa.1981.0002

    Article  Google Scholar 

  17. Zhou M (1985) Fluid mechanics pump and air blower. China Architecture & Building Press, Beijing

    Google Scholar 

  18. Ashgriz N (2011) Handbook of atomization and sprays: theory and applications. Springer Science & Business Media, Berlin

    Book  Google Scholar 

Download references

Funding

This research is supported by National Natural Science Foundation of China (NSFC) under Grant No. 51475030. The authors are indebted to the financial support in the accomplishment of this research.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, China

    Guangyuan Zhu, Songmei Yuan & Bochuan Chen

  2. R&D Center of High-efficient & Green CNC Machining Technology and Equipment, Beihang University, Beijing, 100191, China

    Guangyuan Zhu, Songmei Yuan & Bochuan Chen

Authors
  1. Guangyuan Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Songmei Yuan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Bochuan Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Songmei Yuan.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhu, G., Yuan, S. & Chen, B. Numerical and experimental optimizations of nozzle distance in minimum quantity lubrication (MQL) milling process. Int J Adv Manuf Technol 101, 565–578 (2019). https://doi.org/10.1007/s00170-018-2928-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2928-3

Keywords

Search

Navigation