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.

Copyright © 2013 by ASME
Your Session has timed out. Please sign back in to continue.


Stoll, A., Sebastian, A. J., Klosinski, R., and Furness, R., 2008, “Lean and Environmentally Friendly Manufacturing: Minimum Quantity Lubrication (MQL) is a Key Technology for Driving the Paradigm Shift in Machining Operations,” SAE, Paper No. 2008-01–1128. [CrossRef]
Filipovic, A., and Stephenson, D., 2006, “Minimum Quantity Lubrication (MQL) Application in Automotive Powertrain Machining,” Mach. Sci. Technol., 10, pp. 3–22. [CrossRef]
Kamata, Y., and Obikawa, T., 2007, “High Speed MQL Finish-Turning of Inconel 718 With Different Coated Tools,” J. Mater. Process. Technol., 192, pp. 281–286. [CrossRef]
Rahman, M., Senthil Kumar, A., and Salam, M. U., 2002, “Experimental Evaluation on the Effect of Minimum Quantities of Lubricant in Milling,” Int. J. Mach. Tools Manuf., 42, pp. 539–547. [CrossRef]
Tai, B. L., Dasch, J. M., and Shih, A. J., 2011, “Evaluation and Comparison of Lubricant Properties in Minimum Quantity Lubrication Machining,” Mach. Sci. Technol., 15, pp. 376–391. [CrossRef]
Ke, F., Ni, J., and Stephenson, D. A., 2005, “Continuous Chip Formation in Drilling,” Int. J. Mach. Tools Manuf., 45, pp. 1652–1658. [CrossRef]
Stephenson, D. A., and Agapiou, J. S., 2006, Metal Cutting Theory and Practice, 2nd ed., Taylor and Francis, Boca Raton, FL.
Hussain, M. I., Taraman, K. S., Filipovic, A. J., and Garren, I., 2008, “Experimental Study to Analyze the Workpiece Surface Temperature in Deep Hole Drilling of Aluminum Alloy Engine Blocks Using MQL Technology,” J. Achievement Mat. Manuf. Eng., 31, pp. 485–490.
Agapiou, J., 2010, “Development of Gun-Drilling MQL Process and Tooling for Machining of Compacted Graphite Iron (CGI),” Trans. NAMRI/SME, 38, pp. 73–80.
Bono, M., and Ni, J., 2007, “The Location of the Maximum Temperature on the Cutting Edges of a Drill,” Int. J. Mach. Tools Manuf., 46, pp. 901–907. [CrossRef]
Li, R., and Shih, A. J., 2007, “Tool Temperature in Titanium Drilling,” ASME J. Manuf. Sci. Eng., 129(4), pp. 740–749. [CrossRef]
Fleischer, J., Pabst, J., and Keleman, S., 2007, “Heat Flow Simulation for Dry Machining of Powertrain Castings,” CIRP Ann. Manuf. Technol., 56, pp. 117–122. [CrossRef]
Bono, M., and Ni, J., 2002, “A Model for Predicting the Heat Flow Into the Workpiece in Dry Drilling,” ASME J. Manuf. Sci. Eng., 124(4), pp. 773–777. [CrossRef]
Tai, B. L., Stephenson, D. A., and Shih, A. J., 2012, “An Inverse Heat Transfer Method for Determining Workpiece Temperature in Minimum Quantity Lubrication Deep Hole Drilling,” ASME J. Manuf. Sci. Eng., 134(2), p. 021006. [CrossRef]


Grahic Jump Location
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

Grahic Jump Location
Fig. 2

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

Grahic Jump Location
Fig. 3

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

Grahic Jump Location
Fig. 4

The inverse heat transfer flow chart to determine hw

Grahic Jump Location
Fig. 5

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

Grahic Jump Location
Fig. 6

Measured torques in four drilling cases

Grahic Jump Location
Fig. 7

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

Grahic Jump Location
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

Grahic Jump Location
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

Grahic Jump Location
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




Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In