Development of a friction model and its application in finite element analysis of minimum quantity lubrication machining of Ti-6Al-4 V

The present investigation reports an experimental and numerical study on minimum quantity lubrication (MQL) machining of Ti-6Al–4 V wherein a friction model as a function of MQL parameters is developed and is subsequently used in finite element analysis of the MQL process. The investigation presents new observations on reduction in specific cutting energy through control on oil-volume flow rate during MQL and thereby affecting the machined surface and tool wear. A tribological study is conducted to construct a friction model as a function of sliding speed, air pressure, and oil-volume flow-rate on the friction coefficient. The predicted and experimentally measured cutting forces in an orthogonal turning operation are in good agreement indicating efficacy of the proposed approach. The mechanisms responsible for affecting the friction and wear patterns are presented