Advertisement

Effects of process parameters and drill point geometry in deep drilling of SAE 4144M under MQL

Technical Paper
  • 67 Downloads

Abstract

Deep drilling is a difficult machining operation, it often presents problems related to chip evacuation and efficiently cooling and lubrication of the cutting zone. Minimum quantity of lubrication (MQL) is an ecological alternative to wet machining. It provides better lubrication, however, it has low cooling effect and the chips are not removed away from the cutting zone by coolant. In this paper a combination of cutting speed, feed-rate and tool geometry is determined to produce smaller chips and lower workpiece temperature for deep drilling of SAE 4144 M steel under MQL lubrication condition. Full factorial design of experiment was used to plan the set of the experiments. Tool wear behavior and cross sections of the drilled holes were compared to a pressurized oil condition. Split point geometry, lower cutting speed and higher feed-rate resulted in the best chip shape and relatively low workpiece temperature in deep drilling of SAE 4144 M with MQL. The worn drill presented microchipping, adhered workpiece material on the rake face and exposed substrate resulted from abrasion of TiNAl coating. MQL resulted in longer tool life and more surface defects compared with the pressurized oil condition.

Keywords

Deep drilling MQL Tool wear SAE 4144 M 

References

  1. 1.
    Biermann D, Iokov I, Blum H, Rademacher A, Taebi K, Stuttmeier FT, Klein N (2012) Thermal aspects in deep hole drilling of aluminium cast alloy using twist drills and MQL. Proc Cirp 3:245–250.  https://doi.org/10.1016/j.procir.2012.07.043 CrossRefGoogle Scholar
  2. 2.
    Jung J, Ni J (2003) Prediction of coolant pressure and volume flow rate in the gundrilling process. J Manuf Sci Eng 125:696–702.  https://doi.org/10.1115/1.1621427 CrossRefGoogle Scholar
  3. 3.
    Tnay GL, Wan S, Woon KS, Yeo SH (2016) The effects of dub-off angle on chip evacuation in single-lip deep hole gun drilling. Int J Mach Tools Manuf 108:66–73.  https://doi.org/10.1016/j.ijmachtools.2016.05.008 CrossRefGoogle Scholar
  4. 4.
    Olson WW, Batzer, Sutherland JW (1998) Modeling of chip dynamics in drilling. In: proceedings of CIRP international workshop on modeling of machining operations, Atlanta, Georgia, p 347–361Google Scholar
  5. 5.
    Xavier LF, Elangovan D (2013) Effect parameters for improving deep hole drilling process by conventional method—a review. Int J Eng Res Technol 2(3):1–11Google Scholar
  6. 6.
    Stephenson DA, Agapiou JS (2016) Metal cutting theory and practice. CRC Press, Boca RatonCrossRefGoogle Scholar
  7. 7.
    Khan MMA, Mithu MAH, Dhar NR (2009) Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using vegetable oil based cutting fluid. J Mater Process Tech 209:5573–5583.  https://doi.org/10.1016/j.jmatprotec.2009.05.014 CrossRefGoogle Scholar
  8. 8.
    Taia BL, Stephenson DA, Furness RJ, Shih AJ (2014) Minimum quantity lubrication (MQL) in automotive powertrain machining. Proc Cirp 14:523–528CrossRefGoogle Scholar
  9. 9.
    Wosniak FA, Polli ML, Beltrão PAC (2010) Influence of cutting parameters on deep hole drilling of AISI 4144 Steel. J Manuf Technol Resh 2:232–244Google Scholar
  10. 10.
    Klocke F (2011) Manufacturing processes 1: cutting. Springer, BerlinCrossRefGoogle Scholar
  11. 11.
    Wang X, Huang C, Zou B, Liu H, Wang J (2013) Effects of geometric structure of twist drill bits and cutting condition on tool life in drilling 42CrMo ultrahigh-strength steel. Int J Adv Manuf Technol 64:41–47.  https://doi.org/10.1007/s00170-012-4026-2 CrossRefGoogle Scholar
  12. 12.
    Wosniak FA, Polli ML, Beltrão PAC (2016) Study on tool wear and chip shapes in deep drilling of AISI 4150 steel. J Braz Soc Mech Sci Eng 38(2):473–480.  https://doi.org/10.1007/s40430-015-0379-4 CrossRefGoogle Scholar
  13. 13.
    Ke F, Ni J, Stephenson DA (2006) Chip thickening in deep-hole drilling. Int J Mach Tools Manuf 46(12–13):1500–1507.  https://doi.org/10.1016/j.ijmachtools.2005.09.022 CrossRefGoogle Scholar
  14. 14.
    Wang Y, Li B, Tu G (2012) The study on the chip formation and wear behavior for drilling forged steel S48CS1 V with TiAlN-coated gun drill. Int J Refract Metals Hard Mater 30:200–207.  https://doi.org/10.1016/j.ijrmhm.2011.08.010 CrossRefGoogle Scholar
  15. 15.
    Tasdelen B, Wikblom T, Ekered S (2008) Studies on minimum quantity lubrication (MQL) and air cooling at drilling. Mater Proc Technol 200:339–346.  https://doi.org/10.1016/j.jmatprotec.2007.09.064 CrossRefGoogle Scholar
  16. 16.
    Boubekri N, Shaikh V (2015) Minimum quantity lubrication (MQL) in machining: benefits and drawbacks. J Ind Intell Inf 3(3):205–209Google Scholar

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2018

Authors and Affiliations

  1. 1.Department of MechanicsFederal University of Technology–ParanáCuritibaBrazil

Personalised recommendations