Characterization of fluid film produced by an atomization-based cutting fluid (ACF) spray system during machining

Alexander C. Hoyne, Chandra Nath, Shiv Gopal Kapoor

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

The atomization-based cutting fluid (ACF) spray system has recently been proposed as a cooling and lubrication solution for machining hard to machine materials (e.g. titanium alloys). On the tool rake face, the ACF spray system forms a thin film from cutting fluid that penetrates into the tool-chip interface to improve tool life. The objective of this work is to characterize this thin fluid film in terms of thickness and velocity for sets of ACF spray parameters. ACF spray experiments are performed by varying impingement angle in order to observe the nature of the spreading film, and to determine the film thickness at different locations after impingement of the droplets. It is observed that the film spreads radially outward producing three fluid film development zones (i.e. impingement, steady, unsteady). The steady zone is found to be between 3 and 7 mm from the focus (impingement point) of the ACF spray for the set of parameters investigated. An analytical 3D thin fluid film model for the ACF spray system has also been developed based on the equations for continuity of mass and momentum. The model requires a unique treatment of the cross-film velocity profile, droplet impingement and pressure distributions, as well as a strong gas-liquid shear interaction. The thickness profiles predicted by the analytical film model have been validated. Moreover, the model predictions of film velocity and chip flow characteristics during a titanium turning experiment reveal that the fluid film can easily penetrate into the entire tool-chip interface with the use of the ACF spray system.

Original languageEnglish (US)
Title of host publicationASME 2013 International Manufacturing Science and Engineering Conference Collocated with the 41st North American Manufacturing Research Conference, MSEC 2013
DOIs
StatePublished - Dec 18 2013
EventASME 2013 International Manufacturing Science and Engineering Conference Collocated with the 41st North American Manufacturing Research Conference, MSEC 2013 - Madison, WI, United States
Duration: Jun 10 2013Jun 14 2013

Publication series

NameASME 2013 International Manufacturing Science and Engineering Conference Collocated with the 41st North American Manufacturing Research Conference, MSEC 2013
Volume2

Other

OtherASME 2013 International Manufacturing Science and Engineering Conference Collocated with the 41st North American Manufacturing Research Conference, MSEC 2013
Country/TerritoryUnited States
CityMadison, WI
Period6/10/136/14/13

Keywords

  • Atomized droplets
  • Cutting fluid
  • Film formation
  • Machining
  • Modeling

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

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