Understanding the effects of the system parameters of an ultrasonic cutting fluid application system for micro-machining

Tool wear in micro-milling poses a serious limitation to increased production rate, and atomized cutting fluids have been shown to be quite effective in increasing tool life in micro-milling operations. A new compact cutting fluid application system has been designed and developed based on ultrasonic atomization. In order to understand the effects of the system input parameters on system performance, two performance measures have been defined in terms of spray characteristics and experiments have been performed to evaluate the system according to the defined performance measures. Based on the experimental results, the system parameters can be adjusted to obtain the desired spray characteristics, and areas of improvement on the design have been identified.