Podcast
Questions and Answers
What was the cutting speed in the first condition of the experiment?
What was the cutting speed in the first condition of the experiment?
Which lubricant provided good lubrication performance when used with water droplets?
Which lubricant provided good lubrication performance when used with water droplets?
How did MQL with synthetic ester without water affect tool wear?
How did MQL with synthetic ester without water affect tool wear?
What impact did MQL have on cutting temperature compared to dry machining?
What impact did MQL have on cutting temperature compared to dry machining?
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In the experiments with MQL, what material was specifically mentioned for turning applications?
In the experiments with MQL, what material was specifically mentioned for turning applications?
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What was the effect of MQL on dimensional accuracy compared to dry cutting?
What was the effect of MQL on dimensional accuracy compared to dry cutting?
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What percentage of the total manufacturing cost does coolant management represent?
What percentage of the total manufacturing cost does coolant management represent?
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According to Ngoi and Sreejith (2000), what percentage of the product cost does lubrication represent?
According to Ngoi and Sreejith (2000), what percentage of the product cost does lubrication represent?
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What is the estimated permissible exposure level for metalworking fluid aerosol concentration according to NIOSH?
What is the estimated permissible exposure level for metalworking fluid aerosol concentration according to NIOSH?
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What significant advantage does minimum quantity lubrication (MQL) offer compared to conventional lubrication?
What significant advantage does minimum quantity lubrication (MQL) offer compared to conventional lubrication?
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What percentage of the total manufacturing cost does the European Automobile Industry report for lubricants?
What percentage of the total manufacturing cost does the European Automobile Industry report for lubricants?
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What health hazards are associated with exposure to metalworking fluids?
What health hazards are associated with exposure to metalworking fluids?
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What was the primary difference between the Type 125 and Type 105 drills regarding cooling methods?
What was the primary difference between the Type 125 and Type 105 drills regarding cooling methods?
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What impact did MQL have on temperature compared to traditional methods?
What impact did MQL have on temperature compared to traditional methods?
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Which cooling system was used in the experiments along with MQL?
Which cooling system was used in the experiments along with MQL?
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How did the performance of MQL compare to traditional soluble oil methods?
How did the performance of MQL compare to traditional soluble oil methods?
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What was the average diameter of the uncoated K10 carbide drills used in the experiments?
What was the average diameter of the uncoated K10 carbide drills used in the experiments?
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What was the range of cutting speeds used during the drilling experiments?
What was the range of cutting speeds used during the drilling experiments?
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What factor was consistent for both cooling systems during the experiments?
What factor was consistent for both cooling systems during the experiments?
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What was the power consumption observed for the uncoated K10 drills using MQL?
What was the power consumption observed for the uncoated K10 drills using MQL?
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What cooling method showed the highest wear during machining?
What cooling method showed the highest wear during machining?
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In terms of surface finish, which option provided the best results?
In terms of surface finish, which option provided the best results?
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What was the average thrust force for the MQL cooling method in drilling operations?
What was the average thrust force for the MQL cooling method in drilling operations?
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Which tool life comparison was made between MQL and flood cooling methods?
Which tool life comparison was made between MQL and flood cooling methods?
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What reduction in operating cost was observed with the implementation of MQL technology?
What reduction in operating cost was observed with the implementation of MQL technology?
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What depth of cut was employed in the milling operation using MQL?
What depth of cut was employed in the milling operation using MQL?
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How much did the feed rate increase for deep hole drilling when using MQL?
How much did the feed rate increase for deep hole drilling when using MQL?
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What impact did MQL have on operator exposure to MWFs?
What impact did MQL have on operator exposure to MWFs?
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What material was used for the drilling operation analyzed?
What material was used for the drilling operation analyzed?
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What type of drill was used in the experiments?
What type of drill was used in the experiments?
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Study Notes
### Cost of Coolant and Lubrication
- Coolant and coolant management cost represent 7.5% to 17% of total manufacturing cost, compared to only 4% for cutting tools
- Lubrication represents 16% to 20% of product cost, according to Ngoi & Sreejith (2000)
- Coolant cost represents approximately 15% of the operational life cycle cost of a machining process
- Cost of lubricants comprises almost 20% of total manufacturing cost, contrasted with the cost of cutting tools which is only 7.5%
### Health and Safety Concerns of Metal Working Fluids
- More than 100 million gallons of metalworking fluids are used in the USA each year
- Approximately 1.2 million employees are exposed to metalworking fluids in the USA annually
- Permissible exposure levels for metal-working fluid aerosols are 5 mg/m³ (OSHA) and 0.5 mg/m³ (NIOSH)
- Oil mist levels in US automotive parts manufacturing facilities are estimated to be 20-90 mg/m³
- Exposure to high levels of metal working fluids can lead to health issues such as:
- Toxicity
- Dermatitis
- Respiratory disorders
- Cancer
### Advantages of Minimum Quantity Lubrication
- Minimum Quantity Lubrication (MQL) produces dry chips, reducing the cost of drying them
- MQL offers significant potential savings in cutting fluid costs
- MQL addresses concerns related to environmental intrusion and occupational hazards associated with airborne cutting fluid particles
### MQL Experiments and Results
- MQL, applied internally through the tool, resulted in 50% lower measured temperatures compared to MQL applied with an external nozzle
- MQL application in drilling aluminum-silicon alloy produced similar performance in terms of forces, tool wear and quality of holes compared to large quantities of soluble oil
- MQL provided similar power consumption for coated and uncoated K10 carbide drills (0.81 KW and 0.79 KW, respectively)
- Feed force displayed a similar rate of increase with feed length for experiments using both coated and uncoated carbide drills
- Uncoated K10 carbide drills performed better than diamond-coated drills and provided similar results to those obtained by both cooling systems
- MQL at different flow rates was compared to emulsion and compressed air cooling in the drilling of gear wheel steel, with MQL providing the best surface finish results apart from emulsion
- A comparison of flood and MQL in drilling and milling operations resulted in no significant differences in tool life between the two techniques
- MQL significantly reduced average thrust forces, resulting in lower average thrust forces (447 lbs) compared to flood cooling (570 lbs) during drilling
- MQL reduced average operating costs by 15% over a ten year period compared to flood cooling in machining operations
- MQL increased feed rates in deep hole drilling operations from 125 mm/min for wet applications to over 660 mm/min
- MQL provided a longer tool life and reduced cycle time
- MQL significantly reduced operator exposure to MWFs
### MQL Applications
- MQL has been successfully applied to:
- Drilling operations
- Milling operations
- Turning operations
### MQL and Machining Performance
- MQL reduced tangential cutting force at low cutting speeds
- MQL demonstrated a significant reduction in cutting temperature over a wide range of cutting speeds
- MQL resulted in a lower cutting tool wear rate compared to dry machining
- MQL application reduced cutting force, cutting zone temperature, tool wear, and surface roughness in turning
- MQL improved dimensional accuracy in turning
- MQL positively affected tool wear and surface roughness in turning AISI-4340 steel with uncoated carbide inserts
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Description
Explore the financial implications and health risks associated with coolant and lubrication in manufacturing. This quiz covers the percentage costs of these fluids relative to total manufacturing expenses and the safety concerns linked to metalworking fluids exposure in the workplace.
