Dry and minimum quantity lubrication high-throughput drilling of compacted graphite iron

Wenwu Wu*, Ali Kuzu, David Stephenson, Jun Hong, Mustafa Bakkal, Albert Shih

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

9 Citations (Scopus)

Abstract

This research studies the sustainable and high-throughput drilling of compacted graphite iron (CGI), a high strength, lightweight material for automotive powertrain applications. CGI drilling experiments were conducted using a 4 mm diameter coated carbide drill at 26.5 mm/s feed rate. In two repeated tests under three lubrication conditions: dry, dry with through-the-drill compressed air, and through-the-drill minimum quantity lubrication (MQL), the drills were able to produce a maximum of 1,740, 3,150 and 2,948 holes, respectively, before the breakage of the drill. The Joule–Thomson effect due to the expansion of high pressure air from through-the-drill holes at the drill tip, chip shape, chip size and chip speed are investigated. Flank wear of the drill cutting edge is measured and results are correlated to drill life. Results indicate that dry machining of CGI is technically feasible. Chip evacuation and advanced tool cooling are important factors that affect drill life for high-throughput sustainable dry drilling of CGI.

Original languageEnglish
Pages (from-to)652-670
Number of pages19
JournalMachining Science and Technology
Volume22
Issue number4
DOIs
Publication statusPublished - 4 Jul 2018

Bibliographical note

Publisher Copyright:
© 2018 Taylor & Francis Group, LLC.

Funding

We are thankful for the support received from the National Science Foundation (CMMI Grant #1327316), Ford Motor Company (William Dowling and Tim Hall), UNIST (Tim Walker), Kennametal (Qiang Wu), Scientific and Technical Research Council of Turkey (2214A-Abroad research support), National Natural Science Foundation of China (No. 51406165), and China Scholarship Council.

FundersFunder number
National Science Foundation
Division of Civil, Mechanical and Manufacturing Innovation1327316
Ford Motor Company
National Natural Science Foundation of China51406165
Ulsan National Institute of Science and Technology
Türkiye Bilimsel ve Teknolojik Araştirma Kurumu
China Scholarship Council

    Keywords

    • Compacted graphite iron
    • dry machining
    • minimum quantity lubrication
    • sustainable manufacturing

    Fingerprint

    Dive into the research topics of 'Dry and minimum quantity lubrication high-throughput drilling of compacted graphite iron'. Together they form a unique fingerprint.

    Cite this