With MQL, the Advantages are Clear

To be sure, metalworking fluids and MQL are complex issues. Regardless of the method used, the basic objectives of the metalcutting industry are high process reliability and high productivity. In addition to the economic ramifications, ecological aspects play an increasingly important role, offering potential savings in energy and other resources.

All metalworking fluid-related lubrication approaches, including MQL, have a common characteristic: continuous targeted feeding of fluid into the cutting zone. The fluid must be delivered accurately onto the rake angle and flank face of the cutting tool to deliver optimal results, which can best be achieved by means of an internal metalworking fluid supply.

MQL Processes and Advantages

MQL creates an aerosol composed of an oil-air mixture that forms a protective film, which reduces friction and tool wear. The cutting tool is cooled by forced convection via compressed air, wet surfaces and evaporation enthalpy.

Processes such as high-speed cutting or high-feed machining are fundamental prerequisites for cutting successfully with MQL. An MQL-optimized cutting process requires smaller, constant wrap angles to reduce the total heat input into the tool.

Compared with wet machining, MQL is more flexible because smaller amounts of fluid are applied. However, due to this reduction of fluid, it is imperative to pay close attention to the continuous targeted feeding of the cutting tool with the MQL aerosol. Low energy consumption and cleanliness of the parts and chips, as well as effective material compatibility, are further advantages of this method.

MQL and modern MQL systems can be integrated into the digital process chain more easily and quickly than conventional metalworking fluids. Regular measurement of the various parameters—such as concentration and pH value—becomes unnecessary. MQL normally involves using neat oil; therefore, detecting impurities and particle sizes poses few problems.

In the course of MQL machining, the amount of both the oil fed and the compressed air used (volumetric flow and pressure) is recorded in MQL systems. This data can be linked directly to the product and process data in the digital process chain. Thus, at the desired time, all essential process variables—from the cutting tool and machine tool to the feed, speed and lubricant supply—can be monitored.

Considerations such as compressed air consumption and associated power consumption can be adjusted and estimated, according to researcher and author Ivan Iovkov. Although aerosol quality and oil fraction measurement during nozzle discharge are complex tasks, they can be addressed with a unique subjective adjustment by the machine operator for the respective tool.

The following example of high-feed cutting of stainless steel shows the potential benefits of an MQL strategy exceptionally well.

Optimization Using MQL

Until recently, 304L stainless steel primarily had been machined dry. The aim of a project at the technology center of Blaser Swisslube AG, Hasle-Rüegsau, Switzerland, was to add value by optimizing the process with MQL. The first step was to compare various cutting tools and MQL products manufactured by Blaser Swisslube. Subsequently, different processes were evaluated for the best tool size and the best MQL oil. An overall view of the entire process is essential for optimal MQL machining. This includes the MQL device itself and the aerosol, as well as preparation and delivery.

Tools must be properly designed from the start for MQL delivery. Only when a constant, consistent aerosol with effective spray behavior is generated at the tool discharge nozzle can improvements be successfully implemented (Figure 1).

During the test, the MQL product Vascomill MMS FA2 showed impressive performance and helped increase tool life by 243 percent. The product also enabled the feed rate and the cutting speed to be increased, contributing to a total productivity increase of more than 70 percent. The cutting speed went from 426 sfm to 1,279 sfm. Furthermore, the optimal MQL strategy prevented built-up edge on the cutting edge (Figure 2).

Because heat can dissipate easily through the chip, materials such as aluminum alloys, conventional steel and stainless steel offer high potential for success with MQL machining. This is extremely relevant for the aerospace industry, in which Blaser Swisslube is working with two renowned customers in Asia and Europe.

In the field of turbocharger production, in collaboration with a global market leader, tool life increased by a factor of up to 12 when using MQL compared with conventional metalworking fluids (Figure 3). This is because the brittle and hard carbide indexable inserts react to the change in temperature during wet machining, also known as thermal shock. Furthermore, conventional coolant machining requires ductile inserts and coatings.

These are some of the advantages of MQL machining.