An integrated numerical study for using minimum quantity lubrication (MQL) when machining austempered ductile iron (ADI)
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ORIGINAL PAPER
An integrated numerical study for using minimum quantity lubrication (MQL) when machining austempered ductile iron (ADI) A. Eltaggaz1 · Z. Said2 · I. Deiab1 Received: 2 June 2019 / Accepted: 25 June 2020 © Springer-Verlag France SAS, part of Springer Nature 2020
Abstract Machining difficult-to-cut materials is still an ongoing area of research because of the promising advantages of these materials in different industrial applications. Austempered Ductile Iron (ADI) is among the difficult-to-cut materials as it is usually associated with short tool life and poor surface integrity and quality. Flood coolant is an effective approach to eliminate the high generated heat when machining ADI. However, the use of conventional flood coolant is not a sustainable approach. Minimum quantity lubrication (MQL) is one of the environmentally friendly cooling approaches, which has been demonstrated to be an effective near dry machining technique. There is a gap in the open literature in the area of numerical modelling of the thermal and heat transfer behavior when machining ADI. Thus, this research focuses on simulating the cutting heat distribution on the cutting tool during machining of ADI by developing an integrated numerical model (finite element & computational fluid dynamics). Two cooling techniques were used in this work namely; dry and MQL. In terms of dry cutting, the simulated temperature values were in good agreement with the experimental results with an error of 5.74%. Regarding the MQL, there was a 10.74% margin of error between the results from the experimental and the integrated numerical model. Keywords Minimum quantity lubrication · Machining · Austempered ductile iron · Integrated numerical model Abbreviations ADI Austempered Ductile Iron MQL Minimum quantity lubrication FEM Finite element model CFD Computational fluid dynamics ALE Arbitrary Lagranian Eulerian List of symbols 𝜌 Material density c Material specific heat Ṫ Temperature rate 𝜂 Inelastic heat fraction 𝜎 Flow stress 𝜀pl Plastic strain T Thermal softening 𝜒 Ductile softening term K1 Material constant K Material constant
* A. Eltaggaz [email protected] 1
Advanced Manufacturing Laboratory, University of Guelph, Guelph, Canada
École nationale supérieure d’arts et métiers, Lille, France
2
εG Limit strain 𝜀̇ G Limit strain rate T0 Base temperature Tm Melting temperature TG Limit temperature n Hardening exponent β Material constant of the temperature function 𝜓(T) Thermal softening term γ Rake angle θ Clearance angle
1 Introduction The cutting temperature and the thermal behaviour of the cutting process are the key factors affecting the tool wear mechanism and the tool life. Cutting fluids are required to reduce the high heat generated during machining process, particularly when machining difficult-to-cut materials such as austempered ductile iron (ADI) and Ti–6Al–4V [1, 2]. Flood coolant is an effective approach to eliminate the high generated heat when machining ADI. However, the use of conventional
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