Ph.D. Proposal Presentation by Kuan-Ming Li
Friday, May 14, 2004

( Dr. Steven Liang, Chair)

"Predictive Modeling of Near Dry Machining"


The objective of this study is to develop a methodology to analyze the air quality and tool performance in turning process under near-dry condition. Near dry machining is addressed in mid-1990s in order to reduce the machining cost, to alleviate the environment impact, and to improve the product surface quality at the same time. Near dry machining refers to the use of a very small amount of cutting fluid in machining process, typically in the order of 100 ml/hr, which is about ten-thousandth of cutting fluid used in flood–cooling machining. In near dry machining, the cutting fluid is supplied by a lubricant applicator that is connected to a compressed air source. An air-fluid mixture is used instead of pure liquid. In near dry machining, with proper cutting conditions and sufficient lubrication, tool life can be longer than that in complete dry machining and the aerosol concentration will be less than that in flood-cooling machining.

Near dry machining performance can be evaluated based on air quality and tool life. Although previous researches showed near dry machining could be an alternative technology to dry machining and flood-cooling machining, those studies are restricted to qualitative experimental results. It is necessary to develop a systematic methodology for near dry machining analysis on both aerosol generation and tool life prediction. The proposed research will focus on near dry turning because the cutting models for turning process are the basis of other machining processes. Moreover, it is easy to implement the traditional cutting models, such as cutting forces, cutting temperatures and tool wear rates, in turning process. The proposed work consists of the following tasks: (1) Force modeling in near dry turning process and validation; (2) Temperature modeling in near dry turning process and validation; (3) Aerosol generation modeling in near dry turning and validation; (4) Tool wear modeling in near dry turning and validation; and (5) Comparison of air quality and tool performance among dry machining process, near dry machining process, and flood-cooling machining process