Design Of a Nozzle Adapter for

Hybrid Cutting Fluid Delivery In

Straight Turning
A minor project presentation

 Prepared by;  Guided by;

Makhdoom Shakeel Dr. Narayan Agarwal (Guide)
M.Tech-Tool Engineering Rahul Katna (Co-Guide)
2017-2019
00870218617
 Index
1. Introduction
2. MQL (Minimum quantity lubrication)
3. Flood lubrication
4. Literature Review
5. Research Gap Identification
6. Objectives – Minor Project
7. Objectives – Major Project
8. References
 Introduction
 Nowadays, the environmental concern in machining industry is a
fact that is being given much consideration.
 Cutting fluids have been used for at least the last 120 years for
increasing machining productivity but also for maintaining (or
even improving) surface integrity after the process.
 Generally, these cutting fluids are composed by mineral cutting
oils or mixed in water emulsions.
 However, due to the growing environmental consciousness as
well as recent strict regulations, it is being necessary to consider
new alternative cooling-lubrication systems which are more
efficient, cheap, reliable and environmentally sustainable.
 MQL (Minimum Quantity Lubrication)
 Typical oil-based lubricants used in MQL do not have the heat
capacity of water-based coolants.[1]
 MQL does not have comparable chip evacuation abilities to those of
wet machining.[4]
 MQL is still not well suited for deep-hole drilling, energy-intensive
processes such as grinding, special operations like honing and small-
hole drilling, or for difficult-to-machine materials such as titanium
and nickel-based alloys.[11]
 MQL still produces a very fine mist, which can be more difficult to
filter.[4]
 Flood Cooling
 Cutting fluid in flood type of flow also make chip-breaking and
chip-transport easier.
 Flood cooling with mineral oil lubricants incorporate environmental
issues.[1]
 It incorporates high economical aspect.
 On the other hand there are many reports, which indicate that flood
cooling in an end-milling process is more effective than in a
continuous turning process. This is because lubricant can reach the
tool face more easily in milling than turning.[3]
 Literature Review
s.no. Author/Year Title Research

1. O. Pereiraa The use of hybrid CO2+MQL Design, CFD

/2015 in machining operations verification and
manufacture of the
nozzle adapter
2. Erween Abd EVALUATION OF MIST FLOW Analysis of cutting flow
Rahim1 /2016 CHARACTERISTIC AND spray at different angle
PERFORMANCE IN and pressure in MQL.
MINIMUM QUANTITY And obtaining various
LUBRICATION (MQL) machining process
MACHINING. parameters conditions.
 Literature Review contd…
3. Kyung-Hee A study on droplets and The droplet size at
Parka /2010 their distribution for higher pressure is
minimum quantity smaller than that of
lubrication (MQL) lower pressure. In
addition, air pressure
effect on the oil mass
accumulation test. The
important MQL
parameters such as
droplet size and
distribution were studied
in terms of the nozzle
distance and air pressure.
 Literature Review contd…
4. F. Itoigawaa Effects and mechanisms in Effects and
/2005 minimal quantity lubrication mechanisms in
machining of an aluminium minimal quantity
alloy lubrication are
investigated by use
of an intermittent
turning process.
5. Lakhvir Machining performances Review paper
Singh/ 2015 with Minimum Quantity
Lubrication (MQL)
 Literature Review conti…
6. T. Waka Tribological Action and Cutting Using two types of controlled
bayashi Performance of MQL Media in atmosphere machining
/2007 Machining of Aluminium. apparatus, this study
investigated the tribological
action of MQL media and
atmospheric carrier gases.

7. Danilo Improving minimum quantity The use of the MQL cooling-

de lubrication in CBN grinding using lubrication technique
Jesus compressed air wheel cleaning combined with a compressed
Oliveira/ air jet for cleaning the wheel
2012 surface, with the nozzle
placed with an incidence
angle of 30◦, provided
efficient wheel cleaning and,
thus, better results in almost
all analyzed process outputs,
compared to conventional
flood coolant and, especially,
conventional MQL (without a
cleaning jet).
 Literature Review conti…
8. Yusuf A comparison of flood cooling, It demonstrates that both
Kaynak minimum quantity lubrication and MQL and flood cooling
/2018 high pressure coolant on machining conditions do not
and surface integrity of titanium Ti- provide any noticeable
5553 advantages in cutting
Alloy. process of this alloy;
however, high pressure
coolant is much useful in
terms of machining
performance measures.
9. Anuj Effects of Minimum Quantity Supercritical CO2 MQL
Kumar Lubrication (MQL) in machining system improved the tool
Sharma/ processes using conventional and life and showed approx
2016 nanofluid based cutting fluids: A 40% increased material
comprehensive review removal rate as compared
to aqueous flood coolant.
 Literature Review conti…
10. Kishor Kumar Hard machining Machining tests are
Gajrani/2017 performance of performed using
indigenously developed minimum quantity
green cutting fluid using cutting fluid and flood
flood cooling and cooling
minimum quantity
cutting fluid
11. Ashutosh Khatri Investigating tool wear In dry, flood coolant,
/2018 mechanisms in and MQL, all three
machining of Ti-6Al-4V machining
in flood coolant, dry and conditions, abrasion
MQL conditions wear was the most
dominating tool wear
mechanism during
machining
 Literature Review conti…
12. J.A. Machining evaluation of a A new grinding technology has
Sanche hybrid MQL-CO2 grinding been presented. The system
a/2010 technology involves the use of two nozzles:
first, oil is supplied as MQL, and
then a flow of CO2 at 238 K is
in charge of fixing the frozen
oil on the surface of the
abrasive grits, protecting them
from wear and improving sliding
conditions, resulting in a better
surface quality of the
component.
13. P.S. Machining of 6061 6061 aluminium alloy has been
Sreejith/ aluminium alloy with MQL, machined under different
2007 dry and flooded lubricant conditions of dry, MQL and
conditions flooded coolant/lubricant using
diamond-coated carbide inserts.
 Literature Review conti…
14. Mohammadjafar Minimum quantity This table indicates that the
Hadad a/2013 lubrication-MQL proposed analytical method in
turning of AISI 4140 this study is capable to
steel alloy estimate the energy partition
and temperatures
in turning processes.

15 A.D. Batako*/2005 Temperature Using this technique,

measurement in high temperatures measured have
efficiency deep demonstrated good agreement
grinding. with predicted temperatures.
The work has highlighted the
need for further work on the
effectiveness of fluid delivery.
 Literature Review conti…
16. F. Klocke Dry Cutting Cooling lubricants (CL) help to achieve a
(2)/2001 specified result in terms of tool life, surface
finish and accuracy-to-size, and facilitate
chip-breaking and transport.
17.
 Research Gap Identification
With respect to the Literature Review study and
contemplation, following are some of the gaps that are
identified and could be taken into consideration for the
undertaken project experimental study & analysis:-

1. In this a new Hybrid nozzle adapter is designed which

combines flood lubrication and MQL technologies presented.
2. Investigating tool wear in machining with the help of Dry, flooded,
MQL and Hybrid cutting fluid delivery (Flood and MQL) cooling.
3. Temperature analysis of tool bit in Dry, flooded, MQL and Hybrid
cutting fluid delivery (Flood and MQL) cooling.
 Objectives - Minor Project

 Review of existing literature.

 Study of various types of cooling system in machining to
be used and identifying the research Gap.
 Proposing solution based on research gap identified.
 Objectives - Major Project
 Workpiece Material purchasing – AISI 1040 (EN 8) alloy steel.
 Lubricant: Conventional mineral oil based
 Tool material: Uncoated carbide.

 Design and Manufacturing of nozzle adapter for hybrid flow of

cutting fluid.

 Analysis of tool wear through tool maker microscope and tool

temperature by optical pyrometer.

 Finding the best alternative for industry according to our study.

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Thank You