Minimum quantity lubricant flow analysis in end milling processes: a computational fluid dynamics approach

This paper presents the two- dimensional steady-state incompressible analysis for the minimum quantity lubricant flow in milling operation using the computational fluid dynamics (CFD) approach. The analysis of the flow and heat transfer in a four teeth milling cutter operation was performed. A domain of rotating cutter along with the spraying nozzle is defined. Operating cutting and boundary conditions are taken from the literature. A steady-state, pressure-based, planar analysis was performed with viscous, realizable k-? model. A mixture of oils and air were sprayed on to the tool that is considered rotating and is at a temperature near to the melting temperature of the work piece. Flow fields are obtained in the study. Vector plot of the flow field shows that the flow is not evenly distributed the cutter surface as well as the uneven distribution of lubricant in the direction of cutter rotation. It can be seen that the cutting fluid is not completely penetrated in tool edges. The turbulence created by cutter rotation in the proximity of the tool flings the oil drops out of the cutting zone. The nozzle position in relation to feed direction is very important in order to obtain the optimum effect of the MQL flow