Experimental study to analyse the workpiece surface temperature in deep hole drilling of aluminium alloy engine blocks using MQL technology

• Autorzy: Hussain M. I. , Taraman K. S. , Filipovic A. J. , Garrn I.
• Języki publikacji: EN

Abstrakty

EN

Purpose: The objective of this applied research is to investigate the MQL deep hole drilling method, in order to increase productivity and replace the current method of drilling main oil gallery holes in aluminum alloy cylinder blocks that uses MWFs. Design/methodology/approach: The experimentation was performed at the Guhring, Inc. (a tool manufacturing company) in Germany. The MQL drilling machine, machine operators, CNC programming, hole drilling, and tool layouts were be provided by Guhring. The main components of this experiment were the MQL machine with dual channel system, machine tool fixture, special carbide drills, data acquisition system, thermal optical camera to measure surface temperature, and computers. The surface along the axis of the of the oil gallery hole was milled to produce uniform thickness of 2.5 mm. The drill was spinning but not moving into the engine block, the engine block was moving into the drill. All experiments were performed in random order with no replications. The other output variables, surface finish, true position, roundness, straightness, diameter and misalignment, were measured by a surface analyzer and coordinate measuring machine (CMM). Findings: Based on this research it can be concluded that MQL is a viable production solution for DHD in automotive cast aluminum alloy. Good part quality characteristics were achieved using this method with production feeds and speeds. Practical implications: The MQL method has shown potential to be even more productive as compared to traditional deep hole drilling which would result in less capital investment. Originality/value: Good part quality characteristics were achieved using this method with production feeds and speeds.

Słowa kluczowe

EN

minimum quantity lubricant (MQL); aluminum alloys; temperature; deep hole drilling (DHD)

• Wydawca: International OCSCO World Press
• Czasopismo: Journal of Achievements in Materials and Manufacturing Engineering
• Rocznik: 2008
• Tom: Vol. 31, nr 2
• Strony: 485--490
• Opis fizyczny: Bibliogr. 16 poz., wykr.

Twórcy

autor

Hussain M. I.

autor

Taraman K. S.

autor

Filipovic A. J.

autor

Garrn I.

• General Motors Corporation, GMPT Headquarters, 823 Joslyn Road, Pontiac, Michigan 48340, USA,

Bibliografia

• [1] J. Agapiou, D. Stephenson, Analytical and Experimental Studies of Drill Temperature, ASME Transactions Trans. 54 (1994) 116.
• [2] J. Alverio, J. Agapiou, C. Shen, High Speed Drilling of 390 Aluminum, Transaction of NAMRI/SME (1990).
• [3] M. Bono, J. Ni, The location of the maximum temperature on the cutting edges of a drill, International Journal of Machine Tool and Manufacture 46 (2006) 901-907.
• [4] G. Box, D. Behnken, Some new three level designs for the study of quantitative variables, Technometrics 2 (1960) 455-475.
• [5] S. Chung, Temperature estimation in drilling processes by using an observer International Journal of Machine Tool and Manufacturing 45 (2005) 1641-1651.
• [6] J. Fleischer, J. Pabst, S. Keleman, Heat flow simulation for dry machining of power train castings, Annals of CIRP 56/1 (2007).
• [7] S. Kalidas, R. Devor, S.Kapoor, Experimental investigation of the effect of drill coatings on the hole quality under dry and wet conditions, Surface and Coating Technology 148 (2001) 117-128.
• [8] J. Kelly, M. Cottrell, Minimum Lubrication Machining of Aluminum alloys, Journals of Materials Processing Technology 120 (2002) 327-334.
• [9] D. Montgomery, Design and Analysis of Experiments, 2 Edition, New York: John Wiley and Sons, 1984.
• [10] G. Onwubolu, S. Kumar, Response surface methodologybased approach to CNC drilling operations, Journal of Material Processing Technology 171 (2006) 41-47.
• [11] B. Ozcelik, E. Bagci, Experimental and numerical studies on the determination of twist drill temperature in dry drilling, A new approach, Materials and Design 27 (2006) 920-927.
• [12] M. Schwenck, P. Haenle, I. Garrn, D. Gsaenger, R. Birk, M. Hammer, Development of a solid carbide drill for deep hole application using MQL, Guehring oHG, and D Center, Winterlinger Strasse 12 D-72488 Sigmaringen-Laiz.
• [13] J. Strenkowski, C. Hsieh, A. Shih, An analytical finite element technique for predicting thrust force and torque indrilling, International Journal of Machine Tool and Manufacture 44 (2004) 1413-1421.
• [14] K. Taraman, B. Lambert, Application of response surface methodology to the selection of machining variables, AHE Transactions (1972) 111-115.
• [15] T. Ueda, A. Hosokawa, R. Tanaka, T. Furumoto, Influence of MQL on cutting in temperature, 006 The Proceedings of Annual meeting MTTRF, 2006.
• [16] R. Zeilmann, W. Weingaertner, Analysis of temperature during drilling of Ti6Al4V with minimal quantity of lubricant, Journal of Materials Processing Technology 179(2006) 124-127