Investigating the effects of liquid atomization and delivery parameters of minimum quantity lubrication on the grinding process of Al2O3 engineering ceramics

Minimum quantity lubrication (MQL) is a cost-effective and environmentally friendly alternative to flood cooling. MQL spray jet has been shown to have potential to be applied successfully in different machining processes. Since the amount of lubricating liquid employed in MQL jet is very low, it is necessary to generate and apply the MQL spray efficiently. However, efficient application of MQL is not only related to spray atomization characteristics and delivery parameters but is also affected by machining conditions. The present paper demonstrates a theoretical and experimental investigation on the spray atomization and delivery parameters in the grinding process of Al2O3 engineering ceramics. The spray atomization characteristics studied are carrier gas velocity, liquid droplet size and liquid droplet velocity. Experiments were performed to verify the delivery parameters of MQL spray including nozzle angle, nozzle distance, lubricant flow rate and gas flow rate in the case of Al2O3 ceramics grinding. The experimental results confirm the theoretical outcomes and indicate that by applying optimal spray delivery parameters efficient lubrication takes place. Moreover, efficient lubrication of Al2O3 ceramics grinding can decrease the challenges existing in ceramics grinding processes by reducing grinding forces and surface roughness.

► MQL is an efficient and ecologically friendly method of fluid application. ► Efficient lubrication is related to spray atomization and machining conditions. ► MQL spray parameters are investigated theoretically and experimentally. ► By applying optimal spray delivery parameters efficient lubrication takes place. ► MQL can decrease the challenges existing in ceramics grinding process.