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

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
Bruce L. Tai ◽  
David A. Stephenson ◽  
Albert J. Shih
Keyword(s):  
Heat Flux ◽  
Cast Iron ◽  
Heat Generation ◽  
Minimum Quantity Lubrication ◽  
Air Pressure ◽  
Hole Drilling ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Workpiece Temperature ◽  
Minimum Quantity

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.

High Air Pressure in MQL Deep Hole Drilling Workpiece Temperature

2011 ◽  
Vol 189-193 ◽  
pp. 1732-1736 ◽  
Author(s):  
Bruce L. Tai ◽  
David Stephenson ◽  
Steven White ◽  
Albert Shih
Keyword(s):  
Heat Flux ◽  
Minimum Quantity Lubrication ◽  
High Heat ◽  
Heat Fluxes ◽  
Air Pressure ◽  
Hole Drilling ◽  
High Heat Flux ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Workpiece Temperature

This study investigates the effect of air pressure on workpiece temperature in through tool minimum quantity lubrication (MQL) deep-hole drilling. Experiments on 200 mm deep holes drilled by a 10 mm carbide drill were conducted under regular (500 kPa) and high (1000 kPa) air pressure conditions. Torque data shows that the chip clogging problem occurring under regular air pressure can be solved by the high air pressure. An inverse heat transfer method is utilized to quantify the heat fluxes and calculate the temperature distribution during drilling based on embedded thermocouples along the depth. Results show that temperature around the hole increases rapidly when the chips start accumulating in the hole under regular air pressure and cause high heat flux on the drilled hole wall surface. The high pressure condition, prevents chip accumulation, thus reducing the total heat flux.

An Inverse Heat Transfer Method for Determining Workpiece Temperature in Minimum Quantity Lubrication Deep Hole Drilling

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Bruce L. Tai ◽  
David A. Stephenson ◽  
Albert J. Shih
Keyword(s):  
Heat Transfer ◽  
Minimum Quantity Lubrication ◽  
Hole Drilling ◽  
Wall Surface ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Workpiece Temperature ◽  
Hole Wall ◽  
Inverse Heat Transfer ◽  
Transfer Method

This study investigates the workpiece temperature in minimum quantity lubrication (MQL) deep hole drilling. An inverse heat transfer method is developed to estimate the spatial and temporal change of heat flux on the drilled hole wall surfaces based on the workpiece temperature measured using embedded thermocouples and analyzed using the finite element method. The inverse method is validated experimentally in both dry and MQL deep-hole drilling conditions and the results show good agreement with the experimental temperature measurements. This study demonstrates that the heat generated on the hole wall surface is significant in deep hole drilling. In the example of deep hole drilling of ductile iron, the level of thermal power applied on the hole wall surface is about the same as that on the hole bottom surface when a 10 mm drill reached a depth of 120 mm.

Thermal Modeling of Workpiece Temperature in MQL Deep-Hole Drilling

2010 ◽  
Author(s):  
Bruce L. Tai ◽  
David A. Stephenson ◽  
Albert J. Shih
Keyword(s):  
Temperature Distribution ◽  
Minimum Quantity Lubrication ◽  
Hole Drilling ◽  
Bottom Surface ◽  
Transfer Model ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Workpiece Temperature ◽  
Inverse Heat Transfer ◽  
Inverse Solutions

This study investigates the workpiece temperature in minimum quantity lubrication (MQL) deep-hole drilling. An FEA-based inverse heat transfer model is developed to estimate the heat generation based on temperature inputs from embedded thermocouples. The temperature distribution in the workpiece is then calculated by the inverse solutions. The method is validated experimentally using a 10 mm carbide drill drilling cylindrical iron workpiece under both dry and MQL conditions. The calculated temperature distribution shows good agreement with experimental temperature measurements. This study demonstrates that the heat generated on the hole wall surface is as significant in workpiece temperature as that on the hole bottom surface in deep-hole drilling.

Ecological Deep Hole Drilling by Novel Coated and Designed Drill

2007 ◽  
Vol 329 ◽  
pp. 657-662 ◽  
Author(s):  
Yoshihiko Murakami ◽  
Takahiro Yamamoto
Keyword(s):  
Heat Generation ◽  
Minimum Quantity Lubrication ◽  
Hole Drilling ◽  
Cutting Condition ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Tialn Coating ◽  
Titanium Aluminum ◽  
Titanium Aluminum Nitride ◽  
Poly Crystalline Diamond

Ecological deep hole drilling is proposed in this paper. The ecological drilling means a cutting without coolant or minimum quantity lubrication (MQL). Under a cutting condition with a small amount of lubrication, the drills should be designed availably to control heat generation during cutting. An attempt is made on the development of innovative drills which are available for use under ecological cutting conditions. These drills were coated especially with a titanium aluminum nitride (TiAlN) film and a poly crystalline diamond layer. After TiAlN coating flutes of drills were lapped with diamond compounds [1]. The result of studies on the process and application of the innovative drills was reported.

Workpiece Thermal Distortion in Minimum Quantity Lubrication Deep Hole Drilling—Finite Element Modeling and Experimental Validation

2012 ◽  
Vol 134 (1) ◽  
Author(s):  
Bruce L. Tai ◽  
Andrew J. Jessop ◽  
David A. Stephenson ◽  
Albert J. Shih
Keyword(s):  
Heat Flux ◽  
Finite Element ◽  
Heat Carrier ◽  
Three Dimensional ◽  
Minimum Quantity Lubrication ◽  
Hole Drilling ◽  
Bottom Surface ◽  
Thermal Distortion ◽  
Element Analysis ◽  
Minimum Quantity

This paper presents the three dimensional (3-D) finite element analysis (FEA) to predict the workpiece thermal distortion in drilling multiple deep-holes under minimum quantity lubrication (MQL) condition. Heat sources on the drilling hole bottom surface (HBS) and hole wall surface (HWS) are first determined by the inverse heat transfer method. A 3-D heat carrier consisting of shell elements to carry the HWS heat flux and solid elements to carry the HBS heat flux has been developed to conduct the heat to the workpiece during the drilling simulation. A thermal–elastic coupled FEA was applied to calculate the workpiece thermal distortion based on the temperature distribution. The concept of the heat carrier was validated by comparing the temperature calculation with an existing 2-D advection model. The 3-D thermal distortion was validated experimentally on an aluminum workpiece with four deep-holes drilled sequentially. The measured distortion on the reference point was 61 μm, which matches within uncertainty the FEA predicted distortion of 51 μm.

Finite Element Modeling of the Workpiece Thermal Distortion in MQL Deep-Hole Drilling

2011 ◽  
Author(s):  
Bruce L. Tai ◽  
Steven B. White ◽  
David A. Stephenson ◽  
Albert J. Shih
Keyword(s):  
Heat Flux ◽  
Finite Element ◽  
Finite Element Modeling ◽  
Heat Carrier ◽  
Hole Drilling ◽  
Thermal Distortion ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Element Modeling ◽  
Carrier Model

This paper develops a three dimensional (3-D) finite element modeling (FEM) to predict the workpiece thermal distortion in minimum quantity lubrication (MQL) deep-hole drilling. Drilling-induced heat fluxes on the drilled hole bottom surface (HBS) and hole wall surface (HWS) are first determined by the inverse heat transfer method. The proposed 3-D heat carrier model consisting of shell elements to carry the HWS heat flux and solid elements to carry the HBS heat flux conducts the heat to the workpiece to mimic drilling process. A coupled thermal-elastic analysis is used to calculate the workpiece thermal distortion at each time step based on the temperature distribution. The heat carrier model is validated by comparing the temperature profiles at selected points with those from an existing 2-D axisymmetric advection model. The capability for modeling distortion in the case of drilling multiple deep-holes is also demonstrated.

The Performance of Small Diameter Twist Drills in Deep-Hole Drilling

2006 ◽  
Vol 128 (4) ◽  
pp. 884-892 ◽  
Author(s):  
Robert Heinemann ◽  
Srichand Hinduja ◽  
George Barrow ◽  
Gerhard Petuelli
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Small Diameter ◽  
High Speed Steel ◽  
Minimum Quantity Lubrication ◽  
Hole Drilling ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Flute Surface ◽  
Twist Drills

This paper investigates the performance of small diameter high-speed steel twist drills drilling boreholes with a depth of ten times the diameter into carbon steel AISI 1045 using minimum quantity lubrication. The performance of small twist drills is determined, first, by their deep-hole drilling capability, i.e., in how far the cutting forces can be kept at a noncritical level by maintaining the chip disposal, and, second, by their tool life. This work shows that both the deep-hole drilling capability and tool life of small drills are strongly dependent on their geometry, in particular the size of the chip flutes, and the flute surface topography.

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