حامد صفري پور

Today, with increasing concerns about the harmful effects of cutting fluid on the environment, many efforts have been made to reduce the consumption of these fluids. One proposed solution to reduce cutting fluid consumption in machining processes is using the Minimum Quantity of Lubrication (MQL) method. This method improves machining conditions by atomizing the cutting fluid and spraying it on the tool surface. In this research, with the help of Computational Fluid Dynamics (CFD), the velocity gradient of compressed air in a two-fluid nozzle and its surrounding environment was eva‎luated to find the appropriate distance between the nozzle and the tool cutting edge. Based on the obtained results, the distance of the nozzle was determined for the experimental tests. The effect of the MQL and the machining parameters, including cutting fluid flow rate, nozzle air pressure, feed rate, and cutting speed on workpiece surface roughness in the turning process of aluminum alloy 7075, were investigated by employing the Response Surface Method (RSM). A two-fluid nozzle and a minimum lubrication pump were designed and built to perform experimental tests. Based on the results of experimental tests, the lowest surface roughness obtained using parameters of the fluid flow rate of 275 ml/h, the pressure of 3 bar, cutting speed of 200 m/min, and feed rate of 0.08 mm/rev was measured as 0.438 microns. eva‎luating the results showed that the feed rate has a direct relationship with the surface roughness, and as the feed rate increases, the surface roughness also increases. The effect of cutting fluid flow rate parameters, air pressure, and cutting speed on the workpiece surface roughness does not have a consistent trend and depends on the cutting parameters. Therefore, statistical or experimental analysis methods can be utilized to achieve the optimal values of workpiece surface roughness.

ديناميك سيالات محاسباتي , طراحي نازل , پارامترهاي حداقل مقدار روان‌كاري , فرايند تراش‌كاري آلياژ آلومينيوم 7075 , زبري سطح

Computational Fluid Dynamics (CFD) , Nozzle Design , Minimum Quantity of Lubrication (MQL) Parameters , Turning Process of Aluminum Alloy 7075 , Surface Roughness

Hamed Safaripour

Dr. Behnam Davoodi