Ultrasonik Atomizasyon Esaslı Minimum Miktar Yağlama (UMMY) Sistemi İle Tornalamada UMMY İşleme Parametrelerinin Kesme Sıcaklığı ve Yüzey Pürüzlülüğü Üzerine Etkisinin Araştırılması

Year 2026, Volume: 11 Issue: 1 , 1 - 17 , 31.03.2026

Ramazan Mergen , Fırat Kafkas

https://doi.org/10.46578/humder.1829365

https://izlik.org/JA65FE99LC

Abstract

Ultrasonik atomizasyon esaslı minimum miktar yağlama (UMMY) sistemi, kesme bölgesine etkili bir şekilde ulaşarak işleme performansını artırmada önemli bir fayda sağlamaktadır. Kesme sıvısı konsantrasyon oranı (A), nozul orifis çapı (B), yatay nozul açısı (C), dikey nozul açısı (D), nozul mesafesi (E), hava basıncı (F), kesme sıvısı atomizasyon oranı (G) ve nozul tipi (H) gibi parametreler UMMY sisteminin performansını büyük oranda etkilemektedir. Bu çalışmada, UMMY işleme parametrelerinin kesme sıcaklığı ve yüzey pürüzlülüğü üzerindeki etkilerinin incelenmesi ve en uygun parametre değerlerini belirlemek amaçlanmıştır. Bu amaç doğrultusunda, UMMY sistemi kullanılarak AISI 1050 sade karbon çeliğinin tornalanması işlemleri, Taguchi L27 deney tasarım metoduna göre planlanmış ve CNC torna tezgâhında yapılmıştır. UMMY işleme parametrelerinin kesme sıcaklığı ve yüzey pürüzlülüğü üzerine etkileri, varyans analizi (ANOVA) ile tespit edilmiştir. Kısa nozulun, kesme sıcaklığı ve yüzey pürüzlülüğü üzerine en fazla katkısı olan UMMY işleme parametresi olduğu görülmüştür. Kısa nozulun katkı oranı sırasıyla %19.49 ve %17.45’tir. Çoklu yanıt yaklaşımıyla hesaplanan gri ilişkisel analizde optimum UMMY işleme parametreleri Taguchi L27 deney düzeneğindeki 9 numaralı deneyden elde edilmiştir. Buna göre, UMMY işleme parametrelerinin optimum seviyeleri A1B3C3D3E3F3G3H2 şeklinde belirlenmiştir.

Keywords

Ultrasonik atomizasyon , Minimum miktar yağlama (MMY) , Kesme sıcaklığı , Yüzey pürüzlülüğü , Gri ilişkisel analiz , AISI 1050

Investigation of the Effect of Minimum Quantity Lubrication System Based on Ultrasonic Atomization (UMQL) Machining Parameters on Cutting Temperature and Surface Roughness in Turning with UMQL System

https://izlik.org/JA65FE99LC

Abstract

The ultrasonic atomization based minimum quantity lubrication (UMQL) system provides significant benefit in improving machining performance by effectively penetrating the tool-chip interface. The parameters of cutting fluid concentration ratio (A), nozzle orifice diameter (B), horizontal nozzle angle (C), vertical nozzle angle (D), nozzle distance (E), air pressure (F), cutting fluid atomization ratio (G) and nozzle type (H) significantly influence the performance of the UMQL system. In this study, the aim was to investigate the effects of UMQL machining parameters on cutting temperature (T) and surface roughness (Ra), and to determine the most appropriate parameter values. For this purpose, turning of AISI 1050 plain carbon steel using the UMQL system was planned according to the Taguchi L27 experimental design method and experimentally carried out on a CNC lathe. The effects of UMQL machining parameters on cutting temperature and surface roughness were determined by analysis of variance (ANOVA). It was observed that the short nozzle was the UMQL machining parameter that contributed the most to the cutting temperature and surface roughness. The contribution ratio of the short nozzle is 19.49% and 17.45%, respectively. The optimum UMQL machining parameters in the grey relational analysis calculated using the multiple response method were obtained from experiment number 9 in the Taguchi L27 experimental setup. Accordingly, the optimum UMQL processing parameter levels were determined as A1B3C3D3E3F3G3H2

Keywords

Ultrasonic atomization , Minimum quantity lubrication (MQL) , Cutting temperature , Surface roughness , Grey relational analysis , AISI 1050

References

• Kafkas F., & Mergen, R. (2022). İşleme Süreçlerinde Ultrasonik Atomizasyon Kesme Sıvısı (ACF) Püskürtme Sistemine Dayalı Minimum Miktar Yağlama (MQL) Sistemlerine Genel Bir Bakış. Mühendislik Alanında Uluslararası Araştırmalar VI. (Edt: L. Civcik) ISBN: 978-625-8341-51-5. Konya: Eğitim Yayınevi. SS. 7-34.
• Abukhshim, N. A., Mativenga, P. T., & Sheikh, M. A. (2004). An investigation of the tool-chip contact length and wear in high-speed turning of EN19 steel. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 218(8), 889-903.
• Iqbal, S. A., Mativenga, P. T., & Sheikh, M. A. (2007). Characterization of machining of AISI 1045 steel over a wide range of cutting speeds. Part 1: Investigation of contact phenomena. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 221(5), 909-916.
• Ghai, I., Wentz, J., DeVor, R. E., Kapoor, S. G., & Samuel, J. (2010). Droplet behavior on a rotating surface for atomization-based cutting fluid application in micromachining. Journal of manufacturing science and engineering, 132(1).
• Marinov, V. (1999). The tool chip contact length on orthogonal metal cutting. In 5th International Conference on Advanced Engineering and Technology, AMTECH (Vol. 99, pp. 149-155).
• Hoyne, A. C., Nath, C., & Kapoor, S. G. (2015). On cutting temperature measurement during titanium machining with an atomization-based cutting fluid spray system. Journal of Manufacturing Science and Engineering, 137(2), 024502.
• Jun, M. B., Joshi, S. S., DeVor, R. E., & Kapoor, S. G. (2008). An experimental evaluation of an atomization-based cutting fluid application system for micromachining. Journal of manufacturing science and engineering, 130(3).
• Wang, X., Li, C., Zhang, Y., Ding, W., Yang, M., Gao, T., & Ali, H. M. (2020). Vegetable oil-based nanofluid minimum quantity lubrication turning: Academic review and perspectives. Journal of Manufacturing Processes, 59, 76-97.
• Lawal, S. A., Choudhury, I. A., & Nukman, Y. (2012). Application of vegetable oil-based metalworking fluids in machining ferrous metals—a review. International Journal of Machine Tools and Manufacture, 52(1), 1-12.
• Dhar, N. R., Kamruzzaman, M., & Ahmed, M. (2006). Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel. Journal of materials processing technology, 172(2), 299-304.
• Hadad, M., & Sadeghi, B. (2013). Minimum quantity lubrication-MQL turning of AISI 4140 steel alloy. Journal of Cleaner Production, 54, 332-343.
• Khan, M. M. A., Mithu, M. A. H., & Dhar, N. R. (2009). Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using vegetable oil-based cutting fluid. Journal of materials processing Technology, 209(15-16), 5573-5583.
• Shuang, Y., John, M., & Songlin, D. (2019). Experimental investigation on the performance and mechanism of graphene oxide nanofluids in turning Ti-6Al-4V. Journal of Manufacturing Processes, 43, 164-174.
• Shokrani, A., Al-Samarrai, I., & Newman, S. T. (2019). Hybrid cryogenic MQL for improving tool life in machining of Ti-6Al-4V titanium alloy. Journal of Manufacturing Processes, 43, 229-243.
• Ni, C., & Zhu, L. (2020). Investigation on machining characteristics of TC4 alloy by simultaneous application of ultrasonic vibration assisted milling (UVAM) and economical-environmental MQL technology. Journal of Materials Processing Technology, 278, 116518.
• Namlu, R. H., Lotfi, B., & Kılıç, S. E. (2024). Enhancing machining efficiency of Ti-6Al-4V through multi-axial ultrasonic vibration-assisted machining and hybrid nanofluid minimum quantity lubrication. Journal of Manufacturing Processes, 119, 348-371.
• Zhang, M., Wu, B., Zhao, B., Ding, W., & Cui, H. (2024). A novel cooling and lubrication approach: Device development and machining performance evaluation of ultrasonic vibration–assisted MQL. The International Journal of Advanced Manufacturing Technology, 133(3), 1667-1684.
• Namlu, R. H., Çetin, B., Lotfi, B., & Kılıç, S. E. (2024). Investigation of the Combined Effects of Ultrasonic Vibration‐Assisted Machining and Minimum Quantity Lubrication on Al7075‐T6. Journal of Engineering, 2024(1), 6655471.
• Madarkar, R., Agarwal, S., Attar, P., Ghosh, S., & Rao, P. V. (2018). Application of ultrasonic vibration assisted MQL in grinding of Ti–6Al–4V. Materials and manufacturing Processes, 33(13), 1445-1452.
• Namlu, R. H., Sadigh, B. L., & Kiliç, S. E. (2021). An experimental investigation on the effects of combined application of ultrasonic assisted milling (UAM) and minimum quantity lubrication (MQL) on cutting forces and surface roughness of Ti-6AL-4V. Machining Science and Technology, 25(5), 738-775.
• Chen, H., Cheng, W. L., Peng, Y. H., Zhang, W. W., & Jiang, L. J. (2016). Experimental study on optimal spray parameters of piezoelectric atomizer based spray cooling. International Journal of Heat and Mass Transfer, 103, 57-65.
• Ebadian, M. A., & Lin, C. X. (2011). A review of high-heat-flux heat removal technologies. Journal of heat transfer, 133(11).
• Tanveer, A., Marla, D., & Kapoor, S. G. (2017). A thermal model to predict tool temperature in machining of Ti–6Al–4V alloy with an atomization-based cutting fluid spray system. Journal of Manufacturing Science and Engineering, 139(7), 071016.
• Nath, C., Kapoor, S. G., DeVor, R. E., Srivastava, A. K., & Iverson, J. (2012). Design and evaluation of an atomization-based cutting fluid spray system in turning of titanium alloy. Journal of Manufacturing Processes, 14(4), 452-459.
• Nath, C., Kapoor, S. G., Srivastava, A. K., & Iverson, J. (2014). Study of droplet spray behavior of an atomization-based cutting fluid spray system for machining titanium alloys. Journal of manufacturing Science and Engineering, 136(2).
• Nath, C., Kapoor, S. G., & Srivastava, A. K. (2017). Finish turning of Ti-6Al-4V with the atomization-based cutting fluid (ACF) spray system. Journal of Manufacturing Processes, 28, 464-471.
• Nath, C., Kapoor, S. G., Srivastava, A. K., & Iverson, J. (2013). Effect of fluid concentration in titanium machining with an atomization-based cutting fluid (ACF) spray system. Journal of Manufacturing Processes, 15(4), 419-425.
• Martínez-Galván, E., Antón, R., Ramos, J. C., & Khodabandeh, R. (2013). Effect of the spray cone angle in the spray cooling with R134a. Experimental thermal and fluid science, 50, 127-138.
• Abd Rahim, E., & Dorairaju, H. (2018). Evaluation of mist flow characteristic and performance in minimum quantity lubrication (MQL) machining. Measurement, 123, 213-225.
• Singh, R. (2021). Minimum quantity lubrication turning of hard to cut materials–A review. Materials Today: Proceedings, 37, 3601-3605.
• Ueda, T., Hosokawa, A., & Yamada, K. (2006). Effect of oil mist on tool temperature in cutting. Journal of Manufacturing Science and Engineering, 128, 130–135.
• Yassin, A., & Teo, C. Y. (2015). Effect of pressure and nozzle angle of minimal quantity lubrication on cutting temperature and tool wear in turning. In Applied Mechanics and Materials (Vol. 695, pp. 676-679). Trans Tech Publications Ltd.
• Upadhyay, V., Jain, P. K., Mehta, N. K., & Branko, K. (2012). Minimum quantity lubrication assisted turning—an overview. Daaam international scientific book 2012, 463-478.
• Sharma, V. S., Dogra, M., & Suri, N. M. (2009). Cooling techniques for improved productivity in turning. International Journal of Machine Tools and Manufacture, 49(6), 435-453.
• Singh, T., Singh, P., Dureja, J. S., Dogra, M., Singh, H., & Bhatti, M. S. (2016). A review of near dry machining/minimum quantity lubrication machining of difficult to machine alloys. International journal of Machining and Machinability of Materials, 18(3), 213-251.
• Liu, Z. Q., Cai, X. J., Chen, M., & An, Q. L. (2011). Investigation of cutting force and temperature of end-milling Ti–6Al–4V with different minimum quantity lubrication (MQL) parameters. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 225(8), 1273-1279.
• Masoudi, S., Esfahani, M. J., Jafarian, F., & Mirsoleimani, S. A. (2019). Comparison the effect of MQL, wet and dry turning on surface topography, cylindricity tolerance and sustainability. International Journal of Precision Engineering and Manufacturing-Green Technology, 1-13.
• Hou, Y., Liu, X., Liu, J., Li, M., & Pu, L. (2013). Experimental study on phase change spray cooling. Experimental Thermal and Fluid Science, 46, 84-88.
• Kafkas, F. (2022). Evaluation of the efficiency of an ultrasonic atomization-based coolant (uACF) spray system in external turning using different nozzle tips. Journal of Manufacturing Processes, 81, 991-1004.
• Kafkas, F., Gürbüz, H., & Şeker, U. (2022). AISI 316L Paslanmaz Çeliğin Tornalanmasında Takım Geometrisi ve İşleme Parametrelerinin Yüzey Bütünlüğü Özelliklerine Etkisinin Taguchi Yöntemi ile Analizi. Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji, 10 (3), 391-407.
• Palanikumar, K. (2011). Experimental investigation and optimisation in drilling of GFRP composites. Measurement, 44(10), 2138-2148.
• Asiltürk, I., & Akkuş, H. (2011). Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method. Measurement, 44(9), 1697-1704.
• Köksoy, O., & Zehra Muluk, F. (2004). Solution to the Taguchi’s problem with correlated responses. Gazi University Journal of Science, 17(1), 59-70.
• Gupta, A., Singh, H., & Aggarwal, A. (2011). Taguchi-fuzzy multi output optimization (MOO) in high speed CNC turning of AISI P-20 tool steel. Expert Systems with Applications, 38(6), 6822-6828.
• Kalpakjian S., & Schmid SR. (2022). Manufacturing engineering and technology in SI units. 8th Edition. UK: Pearson Education Limited.
• Lin, C. L. (2004). Use of the Taguchi method and grey relational analysis to optimize turning operations with multiple performance characteristics. Materials and manufacturing processes, 19(2), 209-220.
• Acır, A., Canlı, M. E., Ata, İ., & Çakıroğlu, R. (2017). Parametric optimization of energy and exergy analyses of a novel solar air heater with grey relational analysis. Applied Thermal Engineering, 122, 330-338.
• Ramesh, K., Baranitharan, P., & Sakthivel, R. (2019). Investigation of the stability on boring tool attached with double impact dampers using Taguchi based Grey analysis and cutting tool temperature investigation through FLUKE-Thermal imager. Measurement, 131, 143-155.
• Mia, M., Rifat, A., Tanvir, M. F., Gupta, M. K., Hossain, M. J., & Goswami, A. (2018). Multi-objective optimization of chip-tool interaction parameters using Grey-Taguchi method in MQL-assisted turning. Measurement, 129, 156-166.
• Zerti, O., Yallese, M. A., Zerti, A., Belhadi, S., & Girardin, F. (2018). Simultaneous improvement of surface quality and productivity using grey relational analysis based Taguchi design for turning couple (AISI D3 steel/mixed ceramic tool (Al2O3+ TiC)). International Journal of Industrial Engineering Computations, 173-194.
• Tzeng, C. J., Lin, Y. H., Yang, Y. K., & Jeng, M. C. (2009). Optimization of turning operations with multiple performance characteristics using the Taguchi method and Grey relational analysis. Journal of materials processing technology, 209(6), 2753-2759.
• Amiril, S. A. S., Rahim, E. A., & Hishamudin, A. Z. (2019). Effect of nozzle distance and cutting parameters on MQL machining of AISI 1045. In Journal of Physics: Conference Series (Vol. 1150, No. 1, p. 012045). IOP Publishing.
• Huang, W. T., Chou, F. I., Tsai, J. T., & Chou, J. H. (2020). Application of Graphene Nanofluid/Ultrasonic Atomization MQL System in Micromilling and Development of Optimal Predictive Model for SKH-9 High-Speed Steel Using Fuzzy-Logic-Based Multi-objective Design: W.-T. Huang et al. International Journal of Fuzzy Systems, 22(7), 2101-2118.