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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2008

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

Hussain M. I., Taraman K. S., Filipovic A. J., Garrn I.

Journal of Achievements in Materials and Manufacturing Engineering

2008

Vol. 31, nr 2

485-490

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.