Champaign, IL : Illinois Sustainable Technology Center
Abstract
The current trend in the metal-cutting industry is to find ways to completely eliminate or drastically reduce cutting fluid use in most machining operations. Recent advances in tool and machine technology have made it possible to perform some machining without cutting fluid use or with minimum quantity lubrication (MQL). Drilling takes a key position in the realization of dry or MQL machining. Economical mass machining of common metals (e.g., tool and construction-grade steels) requires knowledge of the work piece characteristics as well as the optimal machining conditions. In this study we investigated the effects of using MQL in drilling 1020 and 4140 steels using HSS tools with different coatings and geometries. The treatments selected for MQL in this study are commonly used by industry under flood cooling for these materials. A full factorial experiment was conducted, and the regression models for both surface finish and hole size were generated. The regression models were then used in a Pareto optimization study, and the trade-off between surface finish and hole size deviation from the nominal size was reported. The results showed a definite increase in tool life and better or very acceptable surface quality and size of holes drilled when usingMQL compared with flood cooling.ISTC Sponsored Research Program ; HWR05-192Ope
