IAB meeting (10-14-08) 1

Process Development for Minimum

Quantity Lubrication (MQL)
S. Joshi, P. Kwon, & L. Drzal
Mechanical & Chemical Engineering
Michigan State University
East Lansing, MI
IAB meeting (10-14-08) 2
Objectives
Over 2 billion gallons cutting fluid in 2002
Purpose of cutting fluid: Coolant & Lubricant
Minimum Quantity Lubrication (MQL)
Advantage
No maintenance and waste
Generated Chip can be remelted.
Help to reduce flank wear not crater wear (Anntanasio et al., 2006)
Better surface finish
Key disadvantage
Does not remove chip
Not ideal for high production environment - Evaporation
Use of economical nano-solid lubricants
IAB meeting (10-14-08) 3
As the cutting speed increase, the benefit of MQL diminished
as the oil mist landed on hot cutting tool is evaporated.
100 150 200 250
100
150
200
250
300
350
400
450
f = 0.0762 mm, doc = 0.762 mm, time = 4 min
V (m/min)
L
V
B
(

m
)
Dry
NDM
Wet
Data from S. Liang
MQL
IAB meeting (10-14-08) 4
Introduction
Wavelet transformation analysis and image processing
techniques for measuring droplet size and droplet distribution
Evaluation of wettability in with commercially available oils by
wetting angle test
Lubrication performance of coatings
MQL Parameters which significantly influence the effectiveness
of MQL machining
Droplet size: oil mist size & health concerns
Droplet distribution: nozzle distance & wetting area
Mist pressure & flow rate
Determination of wear progression in ball nosed end milling
of steel with various coatings and lubricants
Modification of MQL oils
IAB meeting (10-14-08) 5
Approaches
Better Lubricant
Use of Nanosolid Lubricant suspended in fluid
Low temperature Graphite (xGnP)
High temperature Boron Nitride (xhBN)
Nanoparticle size enhances attraction to surface
VdWforces very effective at small size
Nanoparticle deposition to the location needed the most
Better Process Parameters
Droplet size and distribution
MQL process pressure and pulse rate
Internal and External: Suspension in fluid carrier
Water, Organic-based oil, Synthetic Ester, A mixture of Water & Oil
IAB meeting (10-14-08) 6
xGnP Exfoliated Graphite Nanoplatelets
xGnP produced based on MSU-IP
Licensed to XG Sciences, Inc
pure graphite nanoplatelets
Between 1 and 10 nm thick
Controllable diameters from 0.5 to 10 m
Surface chemistry selected for compatibility
with carrier fluid
Can be suspended in vegetable oil for use
as a cutting fluid
Stable suspension reached with 1 m
diameter and 0.1 % by weight concentration
1
IAB meeting (10-14-08) 7
A B C D
After 3 days After 7 days
Typical results for suspension stability for tailored surface of xGnP-1
Stability of x-GNP with MQL oil
IAB meeting (10-14-08) 8
xhBN - Exfoliated Boron Nitride Nanoplatelets
xhBN under investigation in Drzal Group
pure Boron Nitride nanoplatelets
Between 1 and 10nm thick
Surface chemistry selected for compatibility
with carrier fluid
IAB meeting (10-14-08) 9
Kwon & Joshi
Droplet Size
MQL Supply
System
HEI
(Height Encoded
Image)
5X 50X
CLSM
(Confocal Laser Scanning
Microscope)
Topography
Image
Oil is Sprayed
onto Silicon Wafer
Droplet Images by
CLSM
IAB meeting (10-14-08) 10
Results
Droplet Volume = 4.98E-4 mm3
Wavelet Transform
Smooth and Adjust
Calculate Droplet Size
HEI
The relationship between 2D and
3D droplet diameters
y = -6E-06x3 + 0.0029x2 +0.079x + 0.0077
IAB meeting (10-14-08) 11
Droplet Distribution
Droplet Distribution
obtaining system
CLSM
(Confocal Laser Scanning
Microscope)
Oil is Sprayed
onto Silicon Wafer
Droplet Images by
CLSM
Droplet images as a
function of P and D
IAB meeting (10-14-08) 12
Droplet Distribution
Microscope image Bitmap image
(by Edge Detection Algorithm)
Droplet Distribution
as a function of air pressure
and nozzle distance
NOZZLE
DISTANCE
NOZZLE AIR PRESSURE
4psi 8psi 12psi
D
av
(um)
N
d
A
f
(%)
D
av
(um)
N
d
A
f
(%)
D
av
(um)
N
d
A
f
(%)
30mm 12.93 888 9.3 11.28 1335 9.6 11.32 2066 15.1
50mm
15.18
595 8.9 12.66 471 4.5 10.54 797 5.0
70mm 13.94 362 4.5 12.29 217 2.0 11.85 217 1.7
90mm 15.47 151 2.4 11.05 485 3.4 11.70 160 1.2
110mm 13.32 144 1.6 11.04 71 0.5 10.15 58 0.3
Average D
2D/3D
14.1/
1.17
(3D)
428 5.34
11.66/
0.96
(3D)
516 4
11.11/
0.92
(3D)
660 4.66
A
f
: Area fraction covered by droplets (%)
N
d
: Droplet count , D
av
: Average diameter (um)
IAB meeting (10-14-08) 13
Wetting Angle
F
VS
: Solid-Vapor Interfacial Force
F
LS
: Liquid-Solid Interfacial Force
F
LV
: Liquid-Vapor Interfacial Force
cos
LV LS VS
F F F =
Wetting Measurement system
Motorized syringe dispense droplet oil
Droplet on the coating surface
CCD Camera captures the image
Software calculate the contact angle
IAB meeting (10-14-08) 14
Wetting Angle
CrSiN
TiSiN
TiAlN
Water Unist
Unist +
Graphite
NRG 100% NRG 1:15
(56.2, 55.2) (17.1, 17.4) (13.9, 16.3) (20.3, 20.1) (32.6, 32.4)
(52.8, 53.4) (10.6, 12.5) (5.3, 6.0) (23.3, 25.6)
(54, 52.1) (26.4, 27.3) (18.3, 18.3) (25.4, 26.2) (35.1, 33.5)
(7.8, 8.5)
IAB meeting (10-14-08) 15
Pressure & Flow Rate Tests
Pressure Dependency
The amount of oil accumulation depends on the outlet
pressure at the nozzle as well as nozzle distance from
the target
Test was done by spraying mist on a paper towel for a
given amount of time & measuring the amount of mass
accumulation
Flow Rate Calculation
Can vary the pulse duration & number of seconds per
pulse
Measured the amount of oil entering the machine at
different pulse durations and rates
IAB meeting (10-14-08) 16
Flow Rate
Pressure Dependency
IAB meeting (10-14-08) 17
Experimental Setup & Parameters
Fixed Values
Tool path
Depth of cut: 1 mm axial & 0.6 mm radial
Feed rate: 2500 mm/min
Variable Values
Spindle speed: 2500/3500/4500 RPM
Hitachi Ball Nose End Mills
CrSiN (f=0.3), TiSiN (f=0.9), TiAlN (f=0.8)
Cooling Conditions
Dry
Compressed air
MQL with Unist Coolube
MQL with Unist Coolube + xGNP
NRG water soluble MQL oil
IAB meeting (10-14-08) 18
Comparative Tests
TiSiN Air Cooling
Central Wear Eight Layers
2500 RPM
TiSiN Dry
Central Wear Eight Layers
2500 RPM
TiSiN MQL - Unist
Central Wear Eight Layers
2500 RPM
IAB meeting (10-14-08) 19
Comparative Tests
TiAlN Unist Low Flow Rate
Flank Wear Eight Layers
3500 RPM
TiAlN Unist + Graphite
Flank Wear Eight Layers
3500 RPM
Chipping greatly reduced
TiAlN Unist
Flank Wear Eight Layers
3500 RPM
IAB meeting (10-14-08) 20
Experimental Plan: Lubricant
Suspension stability
Zeta Potential, Particle size, surface chemistry
Quantification of Surface deposition
Atomic Force Microscopy (AFM)
Environmental Scanning Electron Microscopy (ESEM)
Post Wear Surface Analysis
Captured post cutting fluid analysis
Surface analysis
AFM (roughness)
Auger Electron Spectroscopy (AES) and Xray Photoelectron Spectroscopy
(XPS) (surface atomic and molecular composition)
IAB meeting (10-14-08) 21
Project Proposal 2008-9
Develop Structure-Processing-Property relationships
through research on:
Surface chemistry of xGnP (and xhBN) in MQL oils
Friction & Wear studies in aluminum and steel alloys
Development of optimum process for stable mixture
Refining our understanding of MQL parameters
High pressure + low flow rate lubrication
The size and fraction of x-GNP in MQL oil
Friction study with various lubricants and coatings
Milling tests
IAB meeting (10-14-08) 22
Budget
Labor: $30,000
Supply & Service: $ 9,000
Travel: $ 1,000
Total: $40,000