The atomization-based cutting fluid (ACF) spray system has been found to be effective for improving the tool life and overall productivity during the machining of titanium alloys like Ti–6Al–4 V. The aim of this research is to study droplet spray characteristics of an ACF spray system including droplet entrainment zone (e.g., angle and distance) and droplet-gas co-flow development regions with respect to three ACF spray parameters, viz., droplet and gas velocities, and spray distance. ACF spray experiments are performed by varying droplet and gas velocities. Machining experiments are performed in order to understand the effect of the droplet spray behavior on the machining performance, viz., tool life/wear, and surface roughness during turning of a titanium alloy, Ti–6Al–4 V. The flow development behavior with respect to the spray distance is studied by modeling the droplets entrainment mechanism. The model is validated by the ACF spray experiments. Experiments and the modeling of flow development behavior reveal that a higher droplet velocity and a smaller gas velocity result in smaller droplet entrainment angle leading to a gradual and early development of the co-flow, and a better distribution of the droplets across the jet flare. Machining experiments also show that a higher droplet velocity, a lower gas velocity and a longer spray distance significantly improve tool life and surface finish.
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April 2014
Research-Article
Study of Droplet Spray Behavior of an Atomization-Based Cutting Fluid Spray System for Machining Titanium Alloys
Chandra Nath,
Chandra Nath
Post Doctorate Research Associate
and Visiting Lecturer
Mechanical Science and Engineering,
e-mail: nathc2@asme.org
and Visiting Lecturer
Mechanical Science and Engineering,
University of Illinois at Urbana–Champaign
,Urbana, IL 61801
e-mail: nathc2@asme.org
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Shiv G. Kapoor,
Shiv G. Kapoor
1
Professor
Mechanical Science and Engineering,
e-mail: sgkapoor@ilinois.edu
Mechanical Science and Engineering,
University of Illinois at Urbana–Champaign
,Urbana, IL 61801
e-mail: sgkapoor@ilinois.edu
1Corresponding author.
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Anil K. Srivastava,
Anil K. Srivastava
Chief Technology Officer (CTO),
Manufacturing Research and Development,
Manufacturing Technology,
e-mail: srivastava@techsolve.org
Manufacturing Research and Development,
Manufacturing Technology,
TechSolve Inc.
, Cincinnati, OH 45237
e-mail: srivastava@techsolve.org
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Jon Iverson
Jon Iverson
Vice President (VP)
Machining Services,
Manufacturing Technology,
e-mail: iverson@techsolve.org
Machining Services,
Manufacturing Technology,
TechSolve Inc.
,Cincinnati, OH 45237
e-mail: iverson@techsolve.org
Search for other works by this author on:
Chandra Nath
Post Doctorate Research Associate
and Visiting Lecturer
Mechanical Science and Engineering,
e-mail: nathc2@asme.org
and Visiting Lecturer
Mechanical Science and Engineering,
University of Illinois at Urbana–Champaign
,Urbana, IL 61801
e-mail: nathc2@asme.org
Shiv G. Kapoor
Professor
Mechanical Science and Engineering,
e-mail: sgkapoor@ilinois.edu
Mechanical Science and Engineering,
University of Illinois at Urbana–Champaign
,Urbana, IL 61801
e-mail: sgkapoor@ilinois.edu
Anil K. Srivastava
Chief Technology Officer (CTO),
Manufacturing Research and Development,
Manufacturing Technology,
e-mail: srivastava@techsolve.org
Manufacturing Research and Development,
Manufacturing Technology,
TechSolve Inc.
, Cincinnati, OH 45237
e-mail: srivastava@techsolve.org
Jon Iverson
Vice President (VP)
Machining Services,
Manufacturing Technology,
e-mail: iverson@techsolve.org
Machining Services,
Manufacturing Technology,
TechSolve Inc.
,Cincinnati, OH 45237
e-mail: iverson@techsolve.org
1Corresponding author.
Manuscript received May 31, 2013; final manuscript received September 13, 2013; published online January 3, 2014. Assoc. Editor: Donggang Yao.
J. Manuf. Sci. Eng. Apr 2014, 136(2): 021004 (12 pages)
Published Online: January 3, 2014
Article history
Received:
May 31, 2013
Revision Received:
September 13, 2013
Citation
Nath, C., Kapoor, S. G., Srivastava, A. K., and Iverson, J. (January 3, 2014). "Study of Droplet Spray Behavior of an Atomization-Based Cutting Fluid Spray System for Machining Titanium Alloys." ASME. J. Manuf. Sci. Eng. April 2014; 136(2): 021004. https://doi.org/10.1115/1.4025504
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