Evaluation of nozzle positioning effect on automated coolant supply system performance using a newly developed jig

Thian, Yu Hao (2020) Evaluation of nozzle positioning effect on automated coolant supply system performance using a newly developed jig. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

There are several cutting fluids strategies have been developed, such as dry cutting, flooded cooling, and Minimum Quantity Lubrication (MQL). MQL is proven to achieve a better surface quality while using a lesser amount of cutting fluids. Hence, the fact that more cutting fluid will achieve better surface quality is arguable and has contributed to the development of Automated Coolant System (ACS). ACS utilized Programmable Logic Controller (PLC) to control the supply of cutting fluid by time interval. Therefore, the amount of cutting fluid is reduced. ACS is already developed in previous research works and proven to have better surface quality than flooded cooling. During the previous project, the optimal machining parameters of ACS is already determined. These parameters are the spindle speed, feed rate, depth of cut, and the time interval of cutting fluid supply. However, the nozzle position, which is also one of the important parameters, has yet been studied. In this case, this project aimed to design and fabricate a jig with angle adjustment feature for the ACS and carry out theoretical analysis on the expected result based on literature findings. The design of jig began with the determination of desired Degree of Freedom (DOF), followed by the sketching of jig. 3D modelling is created in Autodesk Inventor by referring to the sketch of ACS jig. The prototype of jig is then produced by using rapid prototyping. The optimal nozzle position angle about the feed direction is predicted on 120°, 150°, 180°, or 210°.The optimal nozzle elevation is expected to be 45° or 50°. 40 mm or 50 mm is predicted to be the optimal nozzle distance. These results are predicted based on theory and research finding which is believed to improve the surface quality of aluminium in end milling.

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