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

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

doi:10.1080/10910344.2017.1402928

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

Department of Mechanical Engineering

School of Mechanical Engineering
University of Michigan, Ann Arbor
Department of Mechanical Engineering
Xi'an Jiaotong University
Department of Mechanical Engineering
Istanbul Technical University
Advanced Manufacturing Technology Development
Ford Motor Company

Research output: Contribution to journal › Article › peer-review

11 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 language	English
Pages (from-to)	652-670
Number of pages	19
Journal	Machining Science and Technology
Volume	22
Issue number	4
DOIs	https://doi.org/10.1080/10910344.2017.1402928
Publication status	Published - 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.

Funders	Funder number
National Science Foundation
Division of Civil, Mechanical and Manufacturing Innovation	1327316
Ford Motor Company
National Natural Science Foundation of China	51406165
Ulsan National Institute of Science and Technology
Türkiye Bilimsel ve Teknolojik Araştirma Kurumu
China Scholarship Council

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 9 Industry, Innovation, and Infrastructure
SDG 12 Responsible Consumption and Production

Keywords

Compacted graphite iron
dry machining
minimum quantity lubrication
sustainable manufacturing

Access to Document

10.1080/10910344.2017.1402928

Cite this

@article{5465c9b593af48ef972efc13207fb2c7,

title = "Dry and minimum quantity lubrication high-throughput drilling of compacted graphite iron",

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{\textendash}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.",

keywords = "Compacted graphite iron, dry machining, minimum quantity lubrication, sustainable manufacturing",

author = "Wenwu Wu and Ali Kuzu and David Stephenson and Jun Hong and Mustafa Bakkal and Albert Shih",

note = "Publisher Copyright: {\textcopyright} 2018 Taylor \& Francis Group, LLC.",

year = "2018",

month = jul,

day = "4",

doi = "10.1080/10910344.2017.1402928",

language = "English",

volume = "22",

pages = "652--670",

journal = "Machining Science and Technology",

issn = "1091-0344",

publisher = "Taylor and Francis Ltd.",

number = "4",

}

TY - JOUR

T1 - Dry and minimum quantity lubrication high-throughput drilling of compacted graphite iron

AU - Wu, Wenwu

AU - Kuzu, Ali

AU - Stephenson, David

AU - Hong, Jun

AU - Bakkal, Mustafa

AU - Shih, Albert

PY - 2018/7/4

Y1 - 2018/7/4

N2 - 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.

AB - 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.

KW - Compacted graphite iron

KW - dry machining

KW - minimum quantity lubrication

KW - sustainable manufacturing

UR - https://www.scopus.com/pages/publications/85042096640

U2 - 10.1080/10910344.2017.1402928

DO - 10.1080/10910344.2017.1402928

M3 - Article

AN - SCOPUS:85042096640

SN - 1091-0344

VL - 22

SP - 652

EP - 670

JO - Machining Science and Technology

JF - Machining Science and Technology

IS - 4

ER -

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

Abstract

Bibliographical note

Funding

UN SDGs

Keywords

Access to Document

Other files and links

Fingerprint

Cite this