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<p>Minimum quantity lubrication (MQL) is a method of applying cutting fluid in the form of mist in machining processes, as opposed to the conventional flood cooling. Inconsistent droplet size distribution is often problematic when larger droplets deviate from the main flow stream, collide, and block small passages, particularly in the through-tool MQL where mist flow is transported through internal channels of a cutting tool. To address this problem, this study proposes a passive filtration method using a spiral inertial filter to create centrifugal force and remove large droplets. The spiral inertial filters with six different geometries are fabricated and integrated into an MQL system. The filtration performance is determined by droplet size distribution measured using Phase Doppler Particle Analyzer (PDPA). The results show preferential removal of the larger droplets over 30&#xa0;µm while the unfiltered flow contains droplet size up to 60&#xa0;µm. However, the smaller droplets travel with relatively little effect on the overall droplet distribution with the arithmetic mean diameter (D10) remaining between 7.8 and 9&#xa0;µm. Further, different geometries do not seem to significantly alter the filtration performance based on a set of statistical analyses. This is likely due to the coupled effect from turbulent flow (Re &gt; 20,000) that offsets the effect of centrifugal force purely due to geometries variation.</p>

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Passive inertial filtration for large droplet removal in minimum quantity lubrication applications

  • 期刊论文

  • 发表日期：

    2025年11月10日

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  • Dariga Shektybayeva,
  • Stephan M. Agee,
  • Jacob A. McFarland,
  • Bruce L. Tai

摘要

Minimum quantity lubrication (MQL) is a method of applying cutting fluid in the form of mist in machining processes, as opposed to the conventional flood cooling. Inconsistent droplet size distribution is often problematic when larger droplets deviate from the main flow stream, collide, and block small passages, particularly in the through-tool MQL where mist flow is transported through internal channels of a cutting tool. To address this problem, this study proposes a passive filtration method using a spiral inertial filter to create centrifugal force and remove large droplets. The spiral inertial filters with six different geometries are fabricated and integrated into an MQL system. The filtration performance is determined by droplet size distribution measured using Phase Doppler Particle Analyzer (PDPA). The results show preferential removal of the larger droplets over 30 µm while the unfiltered flow contains droplet size up to 60 µm. However, the smaller droplets travel with relatively little effect on the overall droplet distribution with the arithmetic mean diameter (D10) remaining between 7.8 and 9 µm. Further, different geometries do not seem to significantly alter the filtration performance based on a set of statistical analyses. This is likely due to the coupled effect from turbulent flow (Re > 20,000) that offsets the effect of centrifugal force purely due to geometries variation.