System configuration of automated coolant supply for optimal system and surface finish in CNC Milling operation

Md Nor, Farizan (2024) System configuration of automated coolant supply for optimal system and surface finish in CNC Milling operation. Doctoral thesis, Universiti Teknikal Malaysia Melaka.

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Abstract

During the machining process, flood cooling is mostly utilized to cool and lubricate the interface between the cutting tool and the work piece. The negative health impacts of coolant use combined with the possible financial benefits of utilizing greener machining techniques are forcing manufacturers to change and create alternative lubricant application techniques. Dry machining and Minimum Quantity Lubricant (MQL) machining have emerged as alternatives to flood cooling. Dry machining saves energy by eliminating fluid, but might be less effective for high efficiency, superior surface finish, and demanding cutting conditions. MQL is a coolant-supply technology that improves surface finish, cutting temperature, cutting force, tool life, and dimensional precision by supplying a very small amount of coolant to the cutting zone. Inspiring by the MQL concept, a good surface finishing can be achieved with small amount of coolant. Therefore, this research work is focusing on developing an Automated Coolant Supply (ACS) system in CNC Milling and Turning where Programmable Logic Controller (PLC) system and Arduino are used to control the amount of coolant used during machining by using timer to supply coolant intermittently to achieve a better surface finishing.The automated coolant supply system consists of two main design components. The first core is the design of the nozzle system and the second core is the development of the program. The mechanical part combines jig, piping, nozzle, valve, coupling, and pneumatic fittings. While in the electrical part, all the electrical components such as relays, lighting socket, voltage regulator and valve are linked together to perform the system. The results of this research work showed that the optimal setting for ACS system are cutting speed = 1600 RPM ; feed rate=150 mm/rev ; depth of cut = 0.6 mm ; angle position of nozzle = 135o ; interval time = 23 s ; distance of nozzle 80 mm with the use of nozzle rectangular 1 (5 mm x 1 mm). The best surface roughness and cutting force are achieved at this optimal condition with 0.4787 µm and 9.8488 N respectively. This value is the lowest compared with dry, flooded and Minimum Quantity Lubrication method and it is prooved through asurface morphology observation. By applying this new ACS system, higher machining precision would be obtained, production costs and coolant consumption during machining will be reduced and a greener environment will be achieved. To achieve a better surface roughness, it is recommended that the effect of different interval time settings when turning the coolant ON and OFF (e.g. 5 seconds on and 10 seconds off) should be studied. Additionally, controlling the interval time settings from a smartphone for this system should also be considered and developed as an element of IR4.0.

Item Type:	Thesis (Doctoral)
Uncontrolled Keywords:	Flood cooling, Coolant in machining, Health impacts of coolant
Divisions:	Library > Tesis > FTKIP
Depositing User:	MUHAMAD HAFEEZ ZAINUDIN
Date Deposited:	16 Dec 2024 08:32
Last Modified:	16 Dec 2024 08:32
URI:	http://eprints.utem.edu.my/id/eprint/28309
Statistic Details:	View Download Statistic

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