Optimization of jet position and investigation of the effects of multijet MQCL during end milling of Ti-6Al-4V. (April 2021)

• Record Type: Journal Article
• Authors: Krishnan G, Pradeep; P, Saravanan; Samuel Raj, D.; Hussain, Shuhaib; Ravi Shankar, Varun; Raj, Naveen
• Is Part Of: Journal of manufacturing processes. Volume 64(2021)
• Page Start: 392
• Page End: 408
• Publication Date: 2021-04
• Subjects: Multijet MQCL -- Jet position optimization -- MQL -- Chip morphology -- Friction; Production management -- Data processing -- Periodicals; Manufacturing processes -- Periodicals; Procestechnologie; Productietechniek; Production -- Gestion -- Informatique -- Périodiques; Fabrication -- Périodiques; Manufacturing processes; Production management -- Data processing; Periodicals; 670.5
• DOI: 10.1016/j.jmapro.2021.01.038
• Languages: English
• ISSNs: 1526-6125

Abstract

Graphical abstract: Highlights: The effect of using multi-jets in MQCL (MJMQCL) milling of Ti-6Al-4V is studied. The jet positions are optimized and the lowest force is for jet position - 20°, 90° and 160°, for which there is lubricant coverage during the entire cutting period. Continuous presence of lubricant film lowers friction and evaporation of the cold liquid droplets cools the cutting zone. MJMQCL has lower cutting force, temperature, surface finish and better tool life. Lower serration height of MJMQCL chips are proof of better cooling and lubrication. Abstract: This work proposes a low cost multijet minimum quantity cooling lubrication (MJMQCL) system with three jets for milling Ti-6Al-4V. The position of the center jet (jet 2) is fixed (90°– with respect to the tool entry), while the positions of the outer two jets are varied in steps of 20° to determine their optimum positions. Along with the fixed center jet, a separate stream of cold air is also delivered using a vortex tube. The cutting force is found to be lowest for the jet positions – jet 1−20° and jet 3–160° - as there is lubricant coverage of the cutting zone during the entire 180° of cutter contact for this position. Then, the performance of the MJMQCL system at this optimum position is compared with dry, flood, and minimum quantity lubrication (MQL) in terms of temperature, force, and surface roughness by varying cutting speed and feed. MJMQCL is found to result in lower forces, temperature, surface roughness, and higher tool life due to better cooling and lubrication effects. Chip morphology analysis reveals thin, tightly curled chips are produced in MJMQCL which help in the formation of lubricant film deep into the tool-chip interface thus lowering friction.