Numerical analysis of flow and heat transfer of minimum quantity lubrication in a turning process using inconel alloy

Sustainable manufacturing has received significant attention by many researchers to create products that use processes that are non-polluting and conserve energy. The use of traditional cutting fluids leads to the reduction of tool tip interface temperature and work piece heat generation, resulting in increased tool life and enhanced work piece quality. However, the negative impacts on the environment from the chemical composition of the water-based solvents incur costly disposal methods that are subjected to strict governmental regulations. This work emphasizes the need for environment-friendly lubrication using Minimum Quantity Lubrication (MQL) with additive nanoparticles which reduces harmful fumes and improves cutting performance compared with full-flood cooling lubrication. Utilizing coolant strategies is vital in the manufacturing industry to reduce the tool wear and heat dissipation through the workpiece during machining and consequently enhancing tool life. This becomes more significant when cutting materials, such as Austempered Ductile Iron (ADI), where the amount of heat generated significantly affects the insert life and the mechanical properties of the workpiece. A computational fluid dynamics model will be developed in this study using a CFD software to model the temperature profile and the oil droplet behavior in the cutting zone. The tool temperatures employed in the CFD model will be generated by a numerical frictional model. Experimental and numerical studies indicted the advantages of using nanoparticles for cooling and lubrication. Therefore, the aim of this work is to compare numerically multiple coolant strategies such as minimum quantity lubrication (MQL), flood cooling machining, and dry cooling machining at different flow rates to predict the thermal effects on the tool and to select optimum process parameters.