Investigation of minimal quantity lubrication in turning of waspaloy

Abstract

In order to achieve a more productive and environmentally friendly manufacturing of aerospace propulsion components, minimal quantity lubrication (MQL) can potentially replace the traditionally used flood cooling in different machining operations. These components are manufactured of difficult to machine alloys, which show great hardness even at elevated temperatures. Waspaloy is one of the more demanding super alloys to machine and serve as reference material in this investigation. In this paper, a turning operation is used to investigate the influence of MQL parameters such as oil type together with cutting data on cutting forces and tool wear. As a reference flood and air cooling was used. Two different type of oils were investigated, ester vs. fatty alcohol. The aerosol was directed towards the tool by two different nozzles. Responses that were measured include particle size, aerosol generation capability, cutting forces and tool wear. The experiments were conducted as a D-optimal design of experiments and evaluated by a regression analysis. No evidence of any lubrication effect can be seen. The most plausible explanation of the effects seen is the effects of cooling and heat transfer.