Effect of UMQL Parameters on Cutting Force and Chip Compression Coefficient in Turning with Minimum Quantity Lubrication Based on Ultrasonic Atomization System (UMQL)

Abstract

Minimum quantity lubrication system based on ultrasonic atomization (UMQL) has gained effectiveness in cooling the cutting zone and increasing machining performance by effectively penetrating the tool-chip interface. UMQL machining parameters such as 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 affect the performance of the UMQL system. The aim of this study is to investigate the effects of UMQL machining parameters on average cutting force (Fc) and chip compression coefficient (ζ) and to determine the optimum UMQL machining parameters. For this purpose, the turning of AISI 1050 steel with the UMQL system was carried out according to the Taguchi L27 orthogonal experimental design on a CNC lathe. The effect of UMQL machining parameters on Fc and ζ was determined using analysis of variance according to Taguchi experimental techniques. As a result of the study, the lowest Fc and ζ values were obtained in the machining performed with a short nozzle (K). Cutting fluid concentration ratio contributed the most to Fc with a value of 29.20 %. It was determined that the ζ value increased as the nozzle orifice diameter, horizontal nozzle angle and vertical nozzle angle values increased. In the grey relational analysis using the multiple response method, the optimum UMMY machining parameters levels were A2B1C2D3E2F3G1H2.

Keywords

• Ultrasonic atomization based minimum quantity lubrication (UMQL)
• Cutting force
• Chip compression coefficient
• Grey relational analysis
• AISI 1050

Ultrasonik Atomizasyon Esasına Dayalı Minimum Miktar Yağlama (UMMY) Sistemi İle Tornalamada UMMY Parametrelerinin Kesme Kuvveti ve Talaş Büzüşme Katsayısı Üzerine Etkisi

Abstract

Ultrasonik atomizasyon esasına dayalı minimum miktar yağlama (UMMY) sistemi, takım-talaş ara yüzüne etkili bir şekilde nüfuz ederek kesme bölgesini soğutmada ve işleme performansının artmasında etkinlik kazanmıştır. UMMY sisteminin performansını, 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 UMMY işleme parametreleri önemli ölçüde etkilemektedir. Bu çalışmanın amacı, UMMY işleme parametrelerinin ortalama kesme kuvveti (Fc) ve talaş büzüşme katsayısı (ζ) üzerine etkilerini araştırmak ve optimum UMMY işleme parametrelerini belirlemektir. Bu amaçla UMMY sistemi ile AISI 1050 çeliğin tornalanması, Taguchi L27 ortogonal deney tasarımına göre CNC torna tezgâhında deneysel olarak gerçekleştirilmiştir. Taguchi deney tekniklerine göre UMMY işleme parametrelerinin Fc ve ζ üzerine etkisi varyans analizi kullanılarak tespit edilmiştir. Çalışma sonucunda, en düşük Fc ve ζ değerleri kısa nozulla (K) yapılan işlemede elde edilmiştir. Fc üzerine en fazla %29.20 değeriyle kesme sıvısı konsantrasyon oranı katkı sağlamıştır. Nozul orifis çapı, yatay nozul açısı ve dikey nozul açısı değerlerinin artmasıyla ζ değerinin arttığı tespit edilmiştir. Çoklu yanıt yöntemi kullanılarak yapılan gri ilişki analizinde optimum UMMY işleme parametrelerinin seviyeleri A2B1C2D3E2F3G1H2 şeklindedir.

Keywords

• Ultrasonik atomizasyon esaslı minimum miktar yağlama (UMMY)
• kesme kuvveti
• talaş büzüşme katsayısı
• gri ilişki analizi
• AISI 1050

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