Effect of MQL on the tool life of small twist drills in deep-hole drilling

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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Cutting-fluid flow with chip evacuation during deep-hole drilling with twist drills

European Journal of Mechanics - B/Fluids ◽

10.1016/j.euromechflu.2021.07.003 ◽

2021 ◽

Author(s):

Andreas Baumann ◽

Ekrem Oezkaya ◽

Dirk Schnabel ◽

Dirk Biermann ◽

Peter Eberhard

Keyword(s):

Fluid Flow ◽

Cutting Fluid ◽

Hole Drilling ◽

Deep Hole ◽

Deep Hole Drilling ◽

Twist Drills

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Determining the Tool Life of a Cemented Carbide Drill Using Optimized Process, Delivery System, and Drill Design Parameters in Deep Hole Drilling Using Environment Friendly Machining Method

Volume 3: Design and Manufacturing, Parts A and B ◽

10.1115/imece2010-40408 ◽

2010 ◽

Author(s):

Muhammad I. Hussain ◽

A. Filipovic ◽

J. Dasch ◽

D. Simon

Keyword(s):

Tool Life ◽

Metal Removal ◽

Cemented Carbide ◽

Design Parameters ◽

Innovative Technology ◽

Hole Drilling ◽

Deep Hole ◽

Deep Hole Drilling ◽

High Production ◽

Cemented Carbide Drills

Near dry machining or Minimum Quantity Lubrication (MQL) methodology appears to be a valid solution to meet environmental challenges of metal removal processes. However, in order to implement environmentally friendly machining into high production manufacturing environments, it is imperative to invent a robust solution for a wide variety of machined features. In previous work by the authors, capabilities of the MQL process, calibrated for machining extremely deep holes with length to diameter (L/D) ratio of up to 15, were proven. An optimal machining solution was developed using the Box and Behnken experimental design approach, and it was demonstrated that cemented carbide drills with proper cutting geometry and MQL settings can be used for deep hole drilling of aluminum. This work, focused on developing a production ready application, proved that MQL technology is also robust enough to achieve adequate tool life for high volume manufacturing requirements. It actually exhibited that such approach may even exceed tool life requirements currently enforced for conventional processes using gun drills or G-drills. In addition, machining time was significantly reduced with this innovative technology achieving productivity approximately 7 times higher than in traditional drilling operations. Considering these achievements, MQL has been demonstrated to be the drilling technology of future that will help reducing capital investments into production machinery and minimize landfill discharges of high production manufacturing facilities.

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Chip evacuation force modelling for deep hole drilling with twist drills

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-018-2488-6 ◽

2018 ◽

Vol 98 (9-12) ◽

pp. 3091-3103 ◽

Cited By ~ 7

Author(s):

Ce Han ◽

Dinghua Zhang ◽

Ming Luo ◽

Baohai Wu

Keyword(s):

Hole Drilling ◽

Deep Hole ◽

Deep Hole Drilling ◽

Twist Drills

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Investigating the feasibility of DLC-coated twist drills in deep-hole drilling

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-008-1912-8 ◽

2009 ◽

Vol 44 (9-10) ◽

pp. 862-869 ◽

Cited By ~ 10

Author(s):

Robert K. Heinemann ◽

Sri Hinduja

Keyword(s):

Hole Drilling ◽

Deep Hole ◽

Deep Hole Drilling ◽

Twist Drills

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Roundness Error in Deep Hole Drilling using Twist Drills and Cold Mold Steel 718

Indian Journal of Science and Technology ◽

10.17485/ijst/2017/v10i17/113011 ◽

2017 ◽

Vol 10 (17) ◽

pp. 1-6 ◽

Cited By ~ 1

Author(s):

Anis Farhan Kamaruzaman ◽

Azlan Mohd Zain ◽

Noorfa Haszlinna Mustaffa ◽

Noordin Mohd Yusof ◽

Farhad Najarian ◽

...

Keyword(s):

Hole Drilling ◽

Deep Hole ◽

Roundness Error ◽

Deep Hole Drilling ◽

Twist Drills

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The Study on Evaluation of Hybrid Drilling Command under Deep Hole Drilling

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.579.219 ◽

2012 ◽

Vol 579 ◽

pp. 219-226

Author(s):

Jen Ching Huang ◽

Wei Piao Wu

Keyword(s):

Tool Life ◽

High Speed ◽

Small Hole ◽

Hole Drilling ◽

Deep Hole ◽

Cnc Machine ◽

Drilling Depth ◽

Deep Hole Drilling ◽

Peck Drilling ◽

Custom Macro

The hybrid drilling command was proposed in this study. The hybrid drilling command is established by combined the merit of G73 (high speed peck drilling cycle) and G83 (small hole peck drilling cycle) using custom macro command. The concept of hybrid drilling command is to divide the total drilling depth into several distances and its distance is shortened gradually. The drilling chip is breaking with the G73 in the distance between each one and banishing from the hole with the G83 after drilling a distance each time. The evaluation on the merit of hybrid drilling command was carried out by deep hole drilling test on CNC machine center. After experiments, the hybrid drilling command can reduce wearing, extending the tool life of the driller and shorten processes time.

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Deep-Hole Drilling in Stainless Steel with Small Diameter Twist Drills

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.433-440.552 ◽

2012 ◽

Vol 433-440 ◽

pp. 552-557 ◽

Cited By ~ 1

Author(s):

Gerhard Petuelli ◽

Christoph Nentwig

Keyword(s):

Stainless Steel ◽

Small Diameter ◽

Hole Drilling ◽

Tool Geometry ◽

Twist Drill ◽

Deep Hole ◽

Deep Hole Drilling ◽

The Individual ◽

The Impact ◽

Twist Drills

In this paper results of manufacturing tests are described done in order to evaluate the performances of twist drills of diameter d = 1.2 mm and 1.4 mm respectively, if boring into stainless steel X90CrMoV18 (1.4112). Deep-hole drilling was realized thus, that the depth of the bore hole was greater than 10 times the diameter of the twist drill (L/d >10). In order to reduce the impact on the environment caused by the coolant, it was found that minimum quantity lubrication (MQL) can be applied. Hence, the ecology of the mass production of perforated discs for the food processing industry can be improved. The performance of the several small diameter twist drills was determined and evaluated by, firstly, their deep-hole drilling capability, e.g. assessed by the variation or even increase of cutting forces with increasing depth and travel, whether the forces exceed a critical level due to poor chip extraction. In addition, the suitability to use or rather implement the different small diameter twist drills for high-speed cutting (HSC) and finally the individual tool service life for each investigated twist drill. This research project has shown that the accomplishable performance and operating time are strongly dependent on tool cutting material and the tool geometry, especially the size of the chip flutes of a twist drill, as well as the individual coating of the cutting tools.

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