Lizoel Buss

Minimum quantity lubrication (MQL) technologies possess great potential for improving the sustainability of manufacturing processes, which can reduce the absolute quantity of metalworking fluid (MWF) and also enable near-dry chips that are easier to recycle. During drilling in particular, the MWF is transported to the contact zone through internal cooling channels of the drilling tool. The MWF supply and its associated flow behaviour in the transfer from the outlet of the cooling channels to the contact zone have not been sufficiently investigated yet. Great potential is seen in the proper delivery of the MQL into the contact zone. This work aims to visualize and quantify the cooling lubricant supply into the cutting zone using the MQL technique. The visualization of the MQL application is made possible by high-speed shadowgraphic imaging. Detailed image processing is used to evaluate the resulting images. The developed evaluation routine allows for the assessment of the impact of the main process parameters such as the varying pressure of the aerosol generator and the cooling channel diameter. It is found that the oil leaves the cooling channels at the tip of the drill bit in the form of ligaments. An increase in pressure and cooling channel diameter leads to an increase in the frequency of oil ligament separation. Three main flow regimes are identified with different separation frequencies. Low inlet pressures result in intermittently dispersed droplets. The most upper pressure levels lead to an almost continuous dispersion of the oil. At the same time, the air and oil mass flow rates also increase.

Metalworking operations rely on the successful application of metalworking fluids (MWFs) for effective and efficient operation. Processes such as grinding or drilling often require the use of MWFs for cooling, lubrication, and chip removal. Electrochemical machining processes require electrolyte flow to operate. However, in those machining operations, a fundamental understanding of the mode of action of MWF is lacking due to the unknown flow dynamics and its interaction with the material removal during the process. Important information on the behaviour of MWFs during machining can be obtained from specific experimental flow visualisation studies. In this paper, promising flow visualisation analysis techniques applied to exemplary machining processes (grinding, sawing, drilling, and electrochemical machining) are presented and discussed. Shadowgraph imaging and flow measurements, e.g., particle image velocimetry, allow the identification of typical flow and MWF operating regimes in the different machining processes. Based on the identification of these regimes, efficient machining parameters and MWF applications can be derived. In addition, detailed experimental analyses of MWFs provide essential data for the input and validation of model development and numerical simulations within the Priority Programme SPP 2231 FluSimPro.

The numerical modeling and simulation of particle dispersion during the filling process of a tubular combustion chamber are presented. By means of multiphase large eddy simulations (LES) the particle distribution inside a circular diffuser‐reactor chamber is studied to analyze the two‐phase flow dynamics for metal powder combustion in a tubular reactor with flame propagation. Typical particle accumulations are found that form close to the reactor wall and also particles tend to segregate and preferentially concentrate at vortex surfaces in particle bands. Particle segregation and accumulation effects aside vortex structures are analyzed using the LES approach. The causes of particle segregation and inhomogeneities are studied and measures for its reduction by changes in the reactor design are discussed. Alterations of the diffuser geometry are adapted to minimize the central particle jet formation and the particle distribution inhomogeneities during the filling process.

Minimum Quantity Lubrication (MQL) is a cooling and lubrication variant applied, for instance, in drilling processes. In the present approach, a new vibration-assisted drilling process is analyzed, which has considerable potential for manufacturing of extremely hard materials. Within this process, the MQL gas/liquid transport in the presence of a vibrating and rotating twist drill bit in the borehole is to be studied. Multiphase computational fluid dynamics is applied to analyze and optimize the MQL flow. However, applying conventional CFD methods with discretized continuum equations on a numerical grid is challenging in this process, as the vibrating drill bit frequently closes the gap in the borehole, where even dynamic grid application fails. The ability to use an open-source Smoothed Particle Hydrodynamics (SPH) meshless method to analyze the lubrication media flow is carried out to accurately and efficiently address this problem and overcome the severe limitations of conventional mesh-based methods. For a feasibility study of the method, the MQL air phase in the dynamic drill cavity is analyzed by SPH and validated against conventional CFD method results. The present study shows insufficient results of the SPH method, both in terms of solution plausibility and computational cost, for simulation of the problem at hand.

The microfluid jet polishing (MFJP) process is a manufacturing technology in which small abrasive particles (such as diamond, alumina, and ceria) are premixed with a carrier fluid (typically water) to form a liquid suspension that is pressurized and expelled through a nozzle for material removal. The resulting microjet beam—with a typical nozzle exit diameter in the range from 0.1 to 1.0 mm—impinges the workpiece surface for material removal by erosion and/or abrasion and produces an ultraprecision surface. This work applies a computational fluid dynamics (CFD) model to analyze the key phenomena in the interaction of the liquid suspension and the workpiece surface. The liquid film characteristics (film height, minimum film height, positions of the minimum film height, and hydraulic jump) obtained from the CFD simulations are compared with the results derived from empirical formulations found in the literature. Subsequently, the numerical results are utilized to investigate the impact velocity, pressure distribution, and shear stress caused by the suspension on the workpiece surface. It is observed that the shear stress strongly depends on the injection pressure of the liquid suspension and is weakly dependent on the abrasive suspension concentration (the liquid suspension with different densities, viscosities, and surface tensions). Additionally, the particle behavior is investigated in order to estimate the impact velocity and to identify the impact and erosion zones of the liquid suspension on the workpiece surface. Numerical results indicate that ~50% of total particles are impinging the workpiece surface almost perpendicularly (with a mean impact angle of ~86 degrees) for the first time in the stagnation region, where they are strongly decelerated by the carrier fluid before they reach the workpiece surface. These particles, however, rebound on the surface and are reaccelerated by the carrier fluid, impinging the workpiece surface further in the radial direction.

The goal of reducing oil consumption for lubrication of machining processes can be achieved by means of minimum quantity lubrication (MQL). In minimum quantity lubrication, the cutting fluid is a mixture of air and oil where only a small amount of the latter is added to the mixture. However, this reduced oil consumption must not be detrimental to the effectiveness of the machining process. In order to analyze the performance of minimum quantity lubrication, the two-phase fluid dynamics of the MQL dispersion fluid has to be investigated. In the present work, this two-phase flow for internal lubrication of a drilling process was studied by means of numerical modeling and simulation based on an Eulerian–Lagrangian–Eulerian (ELE) model. The Eulerian–Lagrangian–Eulerian model can properly describe the transition between the aerosol and wall liquid film two-phase flow. Attention was focused on the flow in the internal channels of a twist drill. A parametric study was carried out in order to disclose the effects of three different relevant parameters, namely the oil droplet diameter and the mass flow rate at the channel inlet and the drill bit rotational speed, on the MQL cutting fluid flow quality inside the drill bit channel and at the channel outlet.