Effects of Nozzle Design and Tool Rotational Speed on MQL Performance in Machining of Aerospace Materials

Minimum Quantity Lubrication (MQL) is a new technology used nowadays in machining processes and is very promising for near dry machining. Compared to dry machining and flood machining processes MQL has clear economical and ecological advantages. However, MQL implementation is still applied using a trial and error approach. Limited research work has been done on evaluating the effect of MQL on product quality, especially, in aerospace materials (composites and difficult to cut materials like Inconel). Therefore an extensive study is critically needed for understanding and optimization of MQL application in machining of aerospace materials thereby increasing the applicability of the technique. In this project, an experimental investigation will be carried out to evaluate the performance of two MQL systems in machining of aerospace materials for external supply. This will help in understanding the parameters of MQL and thereby optimizing the effect of these parameters on the cutting forces, temperature, tool wear, surface roughness, which affect the product integrity and mechanical performance. Multi-phase flow visualization will be carried out to understand the effect of tool rotation and the nozzle configuration on the flow behavior to optimize the MQL system by using PDA. An investigation of the performance of new green cutting fluids on machining process and a study of tribological aspect (MQL, dry, air, and flood) will also be performed to examine their effects on the performance of the machining (milling/routing) aerospace materials.

Faculty Supervisor:

Dr. Helmi Attia

Student:

Amit Shriram Tendolkar

Partner:

Technolub Systemes

Discipline:

Engineering - mechanical

Sector:

Manufacturing

University:

McGill University