This study investigates the milling process through detailed modeling and non-steady-state thermal analysis utilizing a variety of conventional fluids. Milling is a widely used manufacturing process, and understanding its thermal dynamics is critical for optimizing tool performance, enhancing product quality, and extending tool life. The research employs a comprehensive modeling approach that integrates fluid dynamics and heat transfer principles to analyze the thermal behavior during milling operations. By examining different conventional fluids, such as cutting oils and water-based coolants, this study evaluates their effects on temperature distribution, heat generation, and cooling efficiency within the milling zone. The findings highlight significant variations in thermal performance based on fluid selection, revealing the importance of appropriate coolant usage in minimizing tool wear and improving surface finish. Additionally, the non-steady-state thermal analysis provides insights into transient thermal effects that occur during the milling process, which can lead to critical changes in machining conditions. This research contributes to the optimization of milling operations by offering practical recommendations for fluid selection and cooling strategies, ultimately aiming to enhance efficiency and sustainability in manufacturing practices. The results of this study lay the groundwork for future investigations into advanced cooling techniques and their impact on machining performance.

This study investigates the milling process through detailed modeling and non-steady-state thermal analysis utilizing a variety of conventional fluids.