Numerical and Experimental investigation of the droplet size for MQL aerosol under different operating parameters with Flow visualization

Abstract Minimum quantity lubrication (MQL) is a sustainable machining process in which oil and air are mixed to form spray that can be directed the cutting zone. MQL factors like droplet size velocity their effect on remain unclear, especially when employing diverse oils operating settings. Mist formation determine how well droplets lubricate targeted area during machining. Numerical Experimental studies were conducted with different values for parameters type, pressure flow rate, establish best possible combination give ideal surface roughness. The study utilized three types of varied pressures evaluate cooling effectiveness end milling operations. measurements obtained using ‘Phase Doppler Anemometry (PDA)’ ‘Particle Image Velocimetry (PIV)’ techniques. A numerical model within ANSYS Fluent software, computational fluid dynamics (CFD), predicted properties was validated PIV data. Raising decreased size, while increasing achieve greater overall speed enhanced region. Changing coolant rate or compressed affected Sauter mean diameter (SMD) particles. research showed from 1 bar 3 reduced roughness by 55.40 percent SMD 24.58 120V oil. Among tested, achieved lowest at 0.227 μm under specific conditions: 150 ml hr −1 , bars, 35.5 μ m. These findings provide valuable insights into improving efficiency