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Investigation of Lubricant Oil Film Thickness on Workpiece under Minimum Quantity Lubrication Milling Process 最小量润滑铣削工艺下工件润滑油膜厚度的研究

Q4 ENGINEERING, MECHANICAL

Tribology Online

Pub Date : 2023-10-31 DOI: 10.2474/trol.18.365

Nurrina Rosli, Nur Izzati Khoirunnisa Ismail, Amiril Sahab Abdul Sani, Afifah Mohd Ali

Minimum Quantity Lubrication (MQL) technology has drawn attention as an effective lubrication technique despite its small usage of lubricants during the machining process. The technology has undeniably minimized the manufacturing cost as well as the adverse impacts towards the environment and health of operators. However, the ability of the small droplets of lubricant oil to penetrate the cutting zone must be investigated to enhance the machining performance. The penetration ability can be predicted if the amount of lubricant oil adhered to the workpiece is known. Nonetheless, observing the lubricant behavior is commonly challenged by the existing tools during the machining process. Therefore, a non-intrusive technique must be applied to conscientiously observe the lubricant behavior. In this paper, the thickness of lubricant oil resulted by the droplets accumulation on the workpiece during MQL milling process was measured using a Laser-Induced Fluorescence technique to predict the lubricating effects of the lubricant. The surface roughness of workpiece was also measured to investigate how the thickness of lubricant oil affects the machining performance. Experiments were conducted for MQL milling process of aluminium alloy 6061 under constant value of cutting speed and increasing value of lubricant flow rates. The MQL nozzle was tilted 45°, directed perpendicular to the milling direction and fixed together with the cutting tool to let them move together throughout the milling path. Results analysis was performed on the sample whose cutting tool was halfway to the milling path. As a result, the average lubricant oil film thickness was found to increase and obviously fluctuate with increasing flow rates, ranging from 0.2 mm to 0.7 mm. A careful observation of the lubricant oil thickness near the location of cutting tool also suggested that the droplets of lubricant oil probably struggle to penetrate the cutting zone due to the sudden falls at those locations. Furthermore, the correlation between the thickness of lubricant oil film to the performance of milling process under the MQL spraying condition was successfully made since the results trending of the surface roughness of workpiece shows a well agreement with the trending of lubricant oil film thickness.

最小量润滑(MQL)技术作为一种有效的润滑技术，虽然在加工过程中使用的润滑剂很少，但却受到了广泛的关注。不可否认，该技术最大限度地降低了制造成本，并减少了对环境和作业人员健康的不利影响。然而，为了提高加工性能，必须研究润滑油小液滴穿透切削区的能力。如果知道附着在工件上的润滑油量，则可以预测渗透能力。然而，在加工过程中，观察润滑剂的行为通常受到现有工具的挑战。因此，必须采用非侵入式技术来认真观察润滑剂的行为。本文利用激光诱导荧光技术测量了MQL铣削过程中液滴在工件上积聚而形成的润滑油厚度，以预测润滑油的润滑效果。测量了工件表面粗糙度，研究了润滑油厚度对加工性能的影响。对6061铝合金在一定切削速度和一定润滑油流量下的MQL铣削工艺进行了试验研究。MQL喷嘴倾斜45°，垂直于铣削方向，并与刀具固定在一起，使它们在整个铣削路径中一起移动。对刀具在铣削路径中间的试样进行了结果分析。结果表明，润滑油膜的平均厚度随流量的增加而增加，并有明显的波动，范围在0.2 ~ 0.7 mm之间。仔细观察刀具位置附近的润滑油厚度也表明，由于这些位置的突然下降，润滑油液滴可能难以穿透切削区。此外，由于工件表面粗糙度的变化趋势与润滑油膜厚度的变化趋势吻合较好，成功地建立了MQL喷涂条件下润滑油膜厚度与铣削工艺性能的相关性。

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