Minimum quantity lubrication replaces the traditional method of flood cooling with small amounts of high-efficient lubrication. Limited studies have been performed to determine the characteristics of mist produced during MQL. This study investigated the mist concentration levels produced while drilling 1018 steel using a vegetable based lubricant. ANOVA was performed to determine whether speed and feed rates or their interactions have a significant effect on mist concentration levels and particle diameter. It was observed that the concentration levels obtained under all four speed and feed rate combinations studied exceeded the current OSHA and NIOSH standards.

The temperature distribution in the vicinity of the laser used in direct metal deposition (DMD) plays a critical role in determining the final microstructure and properties of the deposit and the heat-affected zone within the substrate. A system of deposition samples were studied consisting of AISI 1018 steel powder deposited onto an AISI 1018 steel substrate as a single pass or as overwritten multiple passes. The laser power and speed were varied to influence the heat input and the rate of cooling. The use of idealized one dimensional lines allowed for the solution of a quasi-steady state analytical temperature distribution. Numerical predictions were made using the commercial software SysWeld™ for single pass depositions. Peak temperatures and cooling rates were determined at selected locations experimentally using micro-hardness measurements which were supplemented by obtaining thermocouple data taken during deposition. The analytical model, numerical predictions, and experimental results are compared for single pass depositions to determine the extent to which existing commercial codes can accurately model the thermal environment for DMD. / text

It has been reported that minimum quantity lubrication (MQL) provides better tool life compared to flood cooling under some drilling conditions. In this study, I evaluate the performance of uncoated HSS twist drill when machining AISI 1018 steel using a newly developed lubricant designed for MQL (EQO-Kut 718 by QualiChem Inc.). A randomized factorial design was used in the experiment. The results show that a tool life of 1110 holes with a corresponding flank wear of 0.058 mm was realized.

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The material removal process uses cutting tools in order to produce the desired shape of the workpiece. Tool wear has been a problem for cutting tools, since cutting tools wear and break. Research has been accomplished in the tool wear field for tool life and more recently tool wear. The computer generation has created a method to simulate the material removal process. These computer simulations model the cutting tool reaction with the workpiece. Many of the simulation models use finite element analysis to calculate the reaction of the cutting tool. Different finite element models are being used throughout the world for research. This thesis used an updated Lagrangian model in conjunction with Archard's law to predict the wear of the cutting tool. This research used experimental data to correlate with simulation data to see whether or not Archard's law was a good approximation for tool wear. The research used different side rake angles and cutting surface speed to test the simulation. Shear angle, contact length, cutting ratio, and force are used to provide output values to compare the experimental and computer simulation data. The comparative results showed good trends between the experimental and computer simulation data in every comparison. The results also showed a good approximation for the force and contact length values. Archard's law can be used to model wear on cutting tools with further research.