0
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
Your Session has timed out. Please sign back in to continue.

References

Jun, M. B., Joshi, S. S., DeVor, R. E., and Kapoor, S. G., 2008, “An Experimental Evaluation of an Atomization-Based Cutting Fluid Application System for Micromachining,” ASME J. Manuf. Sci. Eng., 130(3), p. 031118. [CrossRef]
Ghai, I., Wentz, J., DeVor, R. E., Kapoor, S. G., and Samuel, J., 2010, “Droplet Behavior on a Rotating Surface for Atomization-Based Cutting Fluid Application in Micromachining,” ASME J. Manuf. Sci. Eng., 132(1), p. 011017. [CrossRef]
Attané, P., Girard, F., and Morin, V., 2007, “An Energy Balance Approach of the Dynamics of Drop Impact on a Solid Surface,” Phys. Fluids, 19, p. 012101. [CrossRef]
Bechtel, S. E., Bogy, D. B., and Talke, F. E., 1981, “Impact of Liquid Drop Against a Flat Surface,” IBM J. Res. Dev., 25(6), pp. 963–971. [CrossRef]
Mao, T., Kuhn, D. C. S., and Tran, H., 1997, “Spread and Rebound of Liquid Droplets Upon Impact on Flat Surfaces,” AIChE J., 43(9), pp. 2169–2179. [CrossRef]
Lim, T., Han, S., Chung, J., Chung, J. K., Ko, S., and Grigoropoulos, C. P., 2009, “Experimental Study on Spreading and Evaporation of Inkjet Printed Pico-Liter Droplet on a Heated Substrate,” Int. J. Heat Mass Transfer, 52, pp. 431–441. [CrossRef]
Adair, K. G., 2009, “Development of a Unique Topology for a Hard Turning Micro-Scale Machine Tool,” M.S. thesis, University of Illinois at Urbana-Champaign, Urbana, IL.
Ellicott, G. J., DeVor, R. E., and Kapoor, S. G., 2009, “Machinability Investigation of Micro-Scale Hard Turning of 52100 Steel,” North Am. Manuf. Res. Inst. SME, 37, pp. 143–150.
Chandra, S., DiMarzo, M., Qiao, Y. M., and Tartarini, P., 1996, “Effect of Liquid-Solid Contact Angle on Droplet Evaporation,” Fire Saf. J., 27, pp. 141–158. [CrossRef]
Wang, C. Y., 1973, “Axisymmetric Stagnation Point Flow Over a Moving Plate,” AIChE J., 19, pp. 1080–1081. [CrossRef]
Chandra, S., and Avedisian, C. T., 1991, “On the Collision of a Droplet With a Solid Surface,” Proc. R. Soc. London, 432, pp. 13–41. [CrossRef]
Schiaffino, S., and Sonin, A. A., 1997, “Molten Droplet Deposition and Solidification at Low Weber Numbers,” Phys. Fluids, 9(11), pp. 3172–3187. [CrossRef]
Tio, K. K., and Sadhal, S. S., 1992, “Dropwise Evaporation—Thermal Analysis of Multidrop Systems,” Int. J. Heat Mass Transfer, 35(8), pp. 1987–2004. [CrossRef]
Walklate, P. J., Weiner, K. L., and Parkin, C. S., 1996, “Analysis of and Experimental Measurements Made on a Moving Air-Assisted Sprayer With Two-Dimensional Air-Jets Penetrating a Uniform Crop Canopy,” J. Agric. Eng. Res., 63(4), pp. 365–377. [CrossRef]
Rukosuyev, M., Goo, C. S., Jun, M. B. G., and Park, S. S., 2010, “Design and Development of Cutting Fluid System Based on Ultrasonic Atomization for Micro-Machining,” North Am. Manuf. Res. Inst. SME, 38, pp. 97–104.
Langlois, W. E., 1965, “A Wedge-Flow Approach to Lubrication Theory,” Q. Appl. Math., 23(1), pp. 39–45.
Dobre, M., and Bolle, L., 2002, “Practical Design of Ultrasonic Spray Devices: Experimental Testing of Several Atomizer Geometries,” Exp. Therm. Fluid Sci., 26(2), pp. 205–211. [CrossRef]

Figures

Grahic Jump Location
Fig. 1

Schematic of experimental setup

Grahic Jump Location
Fig. 2

Axes definitions for single-droplet studies

Grahic Jump Location
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

Grahic Jump Location
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

Grahic Jump Location
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

Grahic Jump Location
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

Grahic Jump Location
Fig. 7

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

Grahic Jump Location
Fig. 8

Parameterization scheme for side-view of the droplet

Grahic Jump Location
Fig. 9

Parameterization scheme for top-view of the droplet

Grahic Jump Location
Fig. 10

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

Grahic Jump Location
Fig. 11

Comparison of calculated and measured droplet volumes

Grahic Jump Location
Fig. 12

Model prediction of heat transfer versus droplet speed

Grahic Jump Location
Fig. 13

Cutting temperature data from Ref. [2]

Grahic Jump Location
Fig. 14

Model prediction of lubrication force versus droplet speed

Grahic Jump Location
Fig. 15

Two-way diagrams for cooling performance

Grahic Jump Location
Fig. 16

Two-way diagrams for lubrication performance

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In