Minimum Quantity Lubrication Machining Basics and Tooling Development

Speakers:
David A. Stephenson, PhD, FSME
Ethan Hughey
Global Powertrain Manufacturing Engineering
Ford Motor Co.

Agenda:
5:30 PM — Arrival, professional networking and meal
6:00 PM — Presentation
6:20 PM — Demo
6:50 PM — Questions and Answers

Minimum Quantity Lubrication (MQL) is a machining lubrication strategy in which high volume water-based flood coolants are replaced with a lean air-oil mist.  It is Ford’s standard (Bill of Process) machining strategy for aluminum and gray iron prismatics and cast and forged crankshafts.  MQL provides substantial improvement in operator exposure to coolants, energy and water use, throughput, total lifecycle cost, and flexibility compared to wet machining.  It also generates a number of interesting engineering problems in the areas of tooling design and heat management.

This talk gives a brief general overview of MQL system types, followed by a review of recent tooling development activities at Ford, including air flow and air speed studies, priming and response time of MQL tooling assemblies, oil delivery balancing for multi-edge tooling assemblies, and improvement of air flow through 3D printed tool bodies.

For more details in MQL check Chapter 15 in his book on Metal Cutting Theory and Practice, 3rd Ed, 2016