Numerical modeling and experimental measurement of MQL impingement over an insert in a milling tool with inner channels

•MQL spray impingement is simulated on a solid surface of a rotating tool for milling process.•Good agreements were observed between numerical and experimental measurement of liquid film size from particle distributions.•High inlet pressure is required for high speed machining to help the oil mist to reach the cutting edge area.•High rotation velocity is required to help the oil mist to reach a sufficient oil amount in the cutting edge area.•High canalizations orientation (75°) is required to reach as fast as possible the correct oil amount to start the milling surfacing process.

This paper compares experimental and numerical simulations of liquid film formation for different rotating velocities of a milling tool. The numerical model used was based on an unsteady Reynolds–Average Navier–Stokes (RANS) formulation and multiphase Lagrangian model for liquid film formation by the droplet impingement model on a solid surface. The details of spray–wall interaction are presented and the model was used to simulate the liquid film formation in the Micro-Quantity Lubrication (MQL) coolant process for different milling tool velocities. The shape and the size of the liquid film obtained by the calculation and the experiments were compared to improve understanding of the MQL cooling process. Overall, good agreement was observed between the numerical and the experimental measurements of liquid film size from an estimated numerical film thickness border. This study provided greater understanding of oil mist behavior. The impingement analyses predicted better lubrication when highly oriented channels and high inlet pressure were used, especially in High Speed Machining.

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