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Research Papers

Workpiece Temperature During Deep-Hole Drilling of Cast Iron Using High Air Pressure Minimum Quantity Lubrication

[+] Author and Article Information
Bruce L. Tai

e-mail: ljtai@umich.edu

David A. Stephenson

e-mail: dsteph79@ford.com

Albert J. Shih

e-mail: shiha@umich.edu
Department of Mechanical Engineering,
University of Michigan, Ann Arbor, MI 48109

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received March 4, 2012; final manuscript received February 26, 2013; published online May 27, 2013. Assoc. Editor: Patrick Kwon.

J. Manuf. Sci. Eng 135(3), 031019 (May 27, 2013) (7 pages) Paper No: MANU-12-1071; doi: 10.1115/1.4024036 History: Received March 04, 2012; Accepted February 26, 2013; Revised February 26, 2013

This research investigates heat generation and workpiece temperature during deep-hole drilling of cast iron under a high air pressure minimum quantity lubrication (MQL). The hole wall surface (HWS) heat flux, due to drill margin friction and high temperature chips, is of particular interest in deep-hole drilling since it potentially increases the workpiece thermal distortion. This study advances a prior drilling model to quantify the effect of higher air pressure on MQL drilling of cast iron, which is currently performed via flood cooling. Experiments and numerical analysis for drilling holes 200 mm in depth on nodular cast iron work material with a 10 mm diameter drill were conducted. Results showed that the low drill penetration rate can cause intermittent chip clogging, resulting in tremendous heat; however this phenomenon could be eliminated through high air pressure or high feed and speed. Conversely, if the drilling process is stable without chip clogging and accumulation, added high air pressure is found to have no effect on heat generation. The heat flux though the HWS contributes over 66% of the total workpiece temperature rise when intermittent chip clogging occurs, and around 20% to 30% under stable drilling conditions regardless of the air pressure. This paper demonstrated the significance of HWS heat flux and the potential of high air pressure used in conjunction with MQL technology.

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Figures

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Fig. 1

Thermal model in the inverse heat transfer method: (a) 2D axisymmetric finite element model configuration and (b) temperature response at the input points

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Fig. 2

The control points to determine the heat flux spatial distribution on HWS

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Fig. 3

Schematic CP heat flux models to determine the temporal change of hw: (a) polynomial model and (b) bilinear model

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Fig. 4

The inverse heat transfer flow chart to determine hw

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Fig. 5

Schematic experimental setup for MQL deep-hole drilling (unit: mm)

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Fig. 6

Measured torques in four drilling cases

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Fig. 7

Temperature data at input points in (a) tests A and B and (b) tests C and D

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Fig. 8

Measured and calculated temperatures at input points in (a) test A (before the severe chip clogging), (b) test B, and (c) tests C/D

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Fig. 9

Temperature distribution in the workpiece during drilling in (a) test A (before the occurrence of severe chip clogging), (b) test B, and (c) test C/D

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Fig. 10

The maximum temperature on HBS (point e) and HWS (point f) around the drill tip at 100 mm drilling depth in (a) test A, (b) test B, and (c) test C/D

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