Cutting parameters in the minimum quantity lubricant (MQL) machining process of a gearbox

Today one of the top priorities in the machining industry is to increase or retain the profit margin through cost reduction. In addition, consumers are becoming increasingly aware of the impact that the life cycle of products has on the environment, at the time of their choice. So companies are required to research and develop sustainable processes or adapt existing ones. This research has been commissioned by a company that had conducted a feasibility study showing the need to replace the machining process based on cutting fluids in their production lines with the MQL lubrication system. This paper aims to find the key process parameters for machining different parts of an automobile gearbox. It particularly focuses on the definition of appropriate cutting parameters for machining under the new condition (MQL); through a statistical method of Design of Experiments (DOE). With recommended parameters significant improvements in the surface roughness of different machined parts are shown. Production costs are also reduced by decreasing spending on lubricants and by optimizing the cycle time that is reached under the new cutting conditions.