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Research Papers

Analysis of Droplet Spreading on a Rotating Surface and the Prediction of Cooling and Lubrication Performance of an Atomization-Based Cutting Fluid System

[+] Author and Article Information
Isha Ghai

Graduate Research Assistant
e-mail: ishaghai@illinois.edu

Johnson Samuel

Postdoctoral Research Associate
e-mail: jsamuel@illinois.edu

Richard E. DeVor

College of Engineering Distinguished Professor of Manufacturing
e-mail: redevor@illinois.edu

Shiv G. Kapoor

Professor and Grayce Wicall Gauthier Chair
e-mail: sgkapoor@illinois.edu
Department of Mechanical Science and Engineering,
University of Illinois,
Urbana, IL 61801

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received June 11, 2010; final manuscript received September 20, 2012; published online May 24, 2013. Assoc. Editor: Patrick Kwon.

J. Manuf. Sci. Eng 135(3), 031003 (May 24, 2013) (12 pages) Paper No: MANU-10-1171; doi: 10.1115/1.4024153 History: Received June 11, 2010; Revised September 20, 2012

Droplet spreading on a rotating surface has been modeled with an aim to design an efficient atomization-based cutting fluid (ACF) system for micromachining processes. To this end, single-droplet impingement experiments are conducted on a rotating surface to capture the 3D shape of a droplet upon impingement. A parameterization scheme is then developed to mathematically define the 3D shape of droplet upon impingement. The shape information is used to develop an energy-based model for droplet spreading. The droplet spreading model captures the experimental results within 10% accuracy. The spreading model is then used to predict the cooling and lubrication for an ACF-based microturning process. The model captures the cooling and lubrication trends observed in microturning experiments. A parametric study is conducted to identify the significant factors affecting the performance of an ACF system. Droplet speed is found to have a dominant effect on both cooling and lubrication performance, particularly, with a low surface tension fluid for cooling and a low surface tension and high viscosity fluid for lubrication.

Copyright © 2013 by ASME
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References

Figures

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Fig. 1

Schematic of experimental setup

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Fig. 2

Axes definitions for single-droplet studies

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Fig. 3

Side-view and top-view of varying surface tension droplets at the end of spreading phase for (a) test 1 and (b) test 9 in Table 2

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Fig. 4

Side-view and top-view of varying viscosity droplets at the end of spreading phase for (a) test 9 and (b) test 13 in Table 2

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Fig. 5

Side-view and top-view of droplets impinging upon surfaces of varying surface speed at the end of spreading phase for (a) test 13 and (b) test 14 in Table 2

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Fig. 6

Side-view and top-view of droplets with varying droplet speed at the end of spreading phase for (a) test 1 and (b) test 3 in Table 2

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Fig. 7

Modeling strategy for the design of an atomization-based cutting fluid system for micromachining

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Fig. 8

Parameterization scheme for side-view of the droplet

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Fig. 9

Parameterization scheme for top-view of the droplet

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Fig. 10

Parameterized images of the side-view and top-view of droplets corresponding to conditions in Figs. 3(a) and 3(b)

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Fig. 11

Comparison of calculated and measured droplet volumes

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Fig. 12

Model prediction of heat transfer versus droplet speed

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Fig. 16

Two-way diagrams for lubrication performance

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Fig. 13

Cutting temperature data from Ref. [2]

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Fig. 14

Model prediction of lubrication force versus droplet speed

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Fig. 15

Two-way diagrams for cooling performance

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