CHAPTER-1

INTRODUCTION















2

1.1 Introduction
Drilling, a well-known material removal process is the operation of producing holes in solid
metal by using a rotating cutter called Drill. Drilling holes is one of the most basics in machining
operations. Metal cutting requires considerable pressure of feed on the cutting edge. In order to
be able to use machine tool efficiency, it is well to get acquainted with them. Different types of
drill machines have been designed so that holes can be made speedily, economically, and
accurately in all kinds of material. They can be broadly classified into two groups-
1) Based on construction:

(a)Portable, (b).Sensitive, (c) Radial (d) Up-right (e) Gang (f) Multi-spindle

2) Based on feed.
(a)Hand driven (b) Power driven
Drilling is widely used in the aerospace, aircraft, and automotive industries. Drill hole quality is
very important for such industries. It consists of surface roughness, roundness deviation, Taper
value, hole oversize, s kewness and etc. Only the proper design of machine tools cannot provide
better drill hole quality and the present growing demand such as higher productivity at lowest
machining cost, fulfillment of customer demand within the lead time, higher profit, friendly
machining operation, safety and etc. Rather combination of machine design and proper setting of
cutting parameters can provide such facilities. Therefore, effective cutting parameter must be
designed with the machine tool design to achieve the customer required quality because the
quality of drilling holes accuracy is very important in the aerospace industries as well as aircraft
industries.
Many of the fluids, which are used to lubricate metal forming and machining, contain
environmentally harmful or potentially damaging chemical constituents. Environmental
concerns, market forces, and legislative requirements are combining to make imperative a search
for new solutions that minimize environmental impact without compromising process
economics.

1.2 Problem statement

Drilling is the important conventional metal cutting operation comprising approximately 30%
of all conventional metal cutting processes. It is widely used in the aerospace, aircraft, and
Automotive industries. But it is necessary to know how drilling hole accuracy can be increased
& cutting fluid cost is minimizes. For the customer satisfaction drill hole quality & cost
minimization is essential. When drilling is performed cutting fluids are applied at a cutting zone.
This cutting fluid reduces temperature and improved drill quality. So we find out the effective
cutting fluids so that cost will be minimized and drill quality improved.






3

1.3 Objectives:
To minimize the cost of cutting fluid.
To determine the effect of cutting fluids on the drilling hole quality.
To determine the optimum cutting fluid on the basis of drilling hole quality

1.4 Methodology:
Literature review: Several literatures related to the present work will be reviewed.
Machining Operation: Drilling operation will be performed under Dry & MQL
conditions
Experimental Investigation: Investigations will be conducted on the drilling holes,
chips morphology.
Result & Discussion: Information obtained from investigation will be analyzed and
discussed.
Recommendations: Finally some recommendations will be made if necessary.


1.5 Theoretical background

1.5.1 Radial drilling machine.

Radial drilling machine is the largest and most versatile used for drilling medium to large and
heavy work pieces. Radial drilling machine belongs to power feed type. The column of radial
drilling machine supports the radial arm, drill head and motor. The radial arm slides up and
down on the column with the help of elevating screw provided on the slide of the column,
which is driven by the motor. The drill head is mounted on the radial arm and moves on the
guide ways provided the radial arm can also be swiveled around the column. The drill head is
equipped with a separate motor to drive the spindle, which carried the drill bit. A drill head
may be moved on the arm manually or by power.



1.5.2 Drilling operation.
In the operation of drill material is removed in the form of chips, new surfaces are cleaved
from the work piece accompanied by a large consumption of energy. The mechanical energy
necessary for the drilling operation is transformed into heat leading to conditions of high
temperature at the tool-chip interface. The resulting temperature causes some effects on
drilling operation. This are-
Increasing tool wear
Reduced tool life
Effect on surface roughness
Effect on the overall quality of the machined work piece



4

1.5.3 Chips formation.
The type of chip produced during metal cutting depends upon the machining conditions and
material being cut. The variable which influences the type of chip produced are as follows:
Properties of material cut especially ductility
Depth of cut
Feed rate
Cutting speed
Type and quality of cutting fluid.
Three different types of chips formed during drilling operation:-
(a) Continuous chip
(b) Discontinuous chip
(c) Continuous chip with a built-up edge.
Continuous chip
A continuous chip is obtained when cutting ductile materials such as low carbon steel, aluminum
and copper. This chip is severally deformed and either comes off in the form of a long string, or
curls into a tight roll. Some very soft and ductile materials with a low strength tend to tear away
from the parent metal of the work-piece rather than shear clearly. This results in a rough surface
that has to be cleaned up by a very keen cutting edge. In addition to ductile work-piece material
the other conditions which favor their formation are fine feed, sharp cutting edge, higher cutting
speeds and larger rack angles.

Fig 1.1 Continuous chips
The factors responsible for the formation of continuous chips are given below:
Ductile material
High cutting speed
Large rack angles
Low friction
Sharp cutting edge
Efficient cutting fluids
The tool life increases and the power consumption reduce, in case of continuous chips. However,
they may interface with the finished job surface and may spoil it.



5

Discontinuous chip
Brittle material such as grey cast iron, lack the ductility necessary for appreciable plastic chip
formation. Consequently the compressed material ahead of tool fails in the brittle manner along
the shear zone producing small fragments. Such chips are called discontinuous chips.

Fig 1.2 Discontinuous chips

Discontinuous chips are associated with brittle materials such as cast iron and free cutting
brass. Low cutting speeds and lack of rack angles can also cause discontinuous chips to
be formed when cutting ductile material such as mild steel.
Continuous chips with a built up edge
When during cutting, the temperature and pressure is quite high it causes the chip material to
weld itself to the tool face near the nose. This is called Built up edge.

Fig 1.3 Continuous chips with a built up edge
Various factors responsible for the production of Continuous chips with a built up edge are as
follows:
Ductile work-piece material
Low cutting speed
Insufficient cutting fluid
High friction in the tool face interface
Dull cutting edge
Small rack angle.







6

1.5.4 Cutting fluids
During drilling heat is generated as a result of the work done. Heat is carried away from the
tool and works by means of cutting fluids which at the same time reduce the friction between
the tools and chip and between tool and work and also facilitates the chip formation. Cutting
fluid usually in the form of a liquid are applied to the chip formation zone to improve the
cutting condition compared to dry conditions. If sufficient quantity of cutting fluid is
properly applied, heat can be removed almost fast as it is generated and the temperature of
tool, work-piece, and chip can be kept within limit.
Functions of Cutting Fluid
Most machining process can be carried out advantageously by using a cutting fluid.
During drilling operation heat and wear are produced.
The various functions of cutting fluid are as follows:
It cools the cutting tool and work-piece
It gives better surface finish
Friction can be reduced
It washes away the chips from the tool
It prevents corrosion of work and machine.
Type of Cutting Fluid
A cutting fluid mainly serves following functions:
(a) Cooling: The cooling function is achieved by supplying an adequate volume of
cutting fluid.

(b) Lubrication: Lubricating the cutting tool reduces the coefficient of friction
between chip and tool.

(c) Antiwelding: The cutting fluid prevents intimate contact between the surface
of chip and tool face.
Effect of Cutting Fluid on Cutting speed and Tool Life
Cutting fluid also affect the cutting speed permitted by the cutting tool. The cutting speed can be
increased by about 40% in comparison to machining dry if the emulsion cutting fluid is cooled to
+2C before used. The increase in tool life is about 50% in case of carbon tool steel when using
cutting the fluid as compared to dry machining. Whereas the increase in tool life is 25% in case
of high speed steel tools and 5 to 10% in case of carbide tools. Tests made by Earnest and
Merchant on a variety of cutting fluids shows that use of cutting fluids generally increases the
chip thickness ratio but that the effect within the normal cutting speed range falls as the cutting
speed is increased.




7

Benefit of Cutting Fluid
The various benefits achieved by using cutting fluids are as follows:
Increased tool life
Better surface finish
Lower tool forces
Better dimensional stability of work piece is obtained
Finished surface are protected from corrosion
1.5.5 Machining Processes
In the machining process generally dry, wet and MQL applications are used. Every condition has
some drawbacks but overall consideration MQL is the more preferable than other. Because if the
cutting fluids is not properly handled and disposed, they might pollute soil, air and water and
thus causing serious harmful impact to environment. It is also been reported that about 10-15%
of the total machining cost are incurred for cutting fluids in wet conditions. Some research
worker showed that the cost associated with cutting fluids is frequently greater than those
associated with cutting tools.
Minimum Quantity Lubrication (MQL)
When dry cutting is not an option because of its drawbacks and difficult cutting conditions and
wet conditions is not an option because of unfavorable consequences of cutting fluids, minimum
quantity cooling and lubrication may be alternative. It helps decrease production costs by 10-
50% as well as minimizing environmental and health hazards. Minimum quantity cooling and
lubrication (MQL) cutting or minimum quantity fluid (MQF) cutting, also refers to as quasi-dry
cutting, can be characterized by a small quantity of coloring and lubricating fluid supplied to the
cutting zone- the amount uaually does not exceed 50ml/h [Klocke F, Eisenblaett G (1997);
Wienrt K, Inasaki I, Sutherland J W, Wakabayashi T(2004)].
Minimum quantity lubrication is based on the principle that a drop of liquid is split by an air
flow, distributed in streaks and transported in the direction of flow of air. The consumption oil in
industrial applications is the range of approximately 10-100 ml/hr [Kamata Y, Obikawa T
(2007)].
Dry machining
If there is no lubricant or other types of coolant have not been used in the machining operation is
known dry machining. Since the cutting fluid has a harmful effect on the environment and the
health of the operator therefore the dry machining has a most wonderful topic.
Advantages of dry machining:
Complete elimination of harmful cutting fluid.
It eliminates cost involved in purchase, storage, handling, utilizing and safe
disposal of the fluid.
Reduction in overall production time and improved working condition.



8



CHAPTER 2

LITERATURE REVIEW
















9

2.1 Literature Review:
Autret (1998) research show the effects of minimum quantity lubrication condition on the cutting
performance of hard turned parts, as compared to completely dry cutting. The process attributes
analyzed here in have included the surface roughness, cutting temperature, cutting forces and
tool life. In the contest of resulting surface roughness, no noticeable difference can be concluded
with the use of near-dry over completely dry condition. In the context of steady-state cutting
temperature, a 10 to 30% reduction is consistently observed when minimum quantity lubrication
condition is applied as opposed to completely dry. In the context of cutting forces, there is no
significant difference with or without the use of minimum quantity lubrication. In the context of
tool life, the study has shown a significant increase of tool life over 30% by minimum quantity
lubrication over a wide range of cutting conditions.
Senthil Kumar et al (2002) explains that a major portion of the energy is consumed in the
formation and removal of chips. The greater the energy consumption, the greater are the
temperature and frictional forces at the tool-face interface and consequently the higher is the tool
wear. Drill wear not only affects the surface roughness of the hole but also influences the life of
the drill bit [Panda et al. 2006]. Wear in drill bit is characterized as flank wear, chisel wear,
crater wear and margin wear [Panda 2006, Sanjay 2005]. Since wear on drill bit dictates the hole
quality and tool life of the drill bit. As it wear, cutting forces increases, the temperature rises and
this accelerates the physical and chemical processes associated with drill wear and therefore drill
wears faster.
Kuram et al. (2010) describes that cutting fluids increases the tool life and improve the efficiency
of the production systems providing both cooling and lubricating the work surface. Cutting fluids
are extensively used in drilling operations as it removes chips from inside the holes, thus
preventing drill breakage. Higher surface finish quality and better dimensional accuracy are also
obtained from cutting fluids. Many types of cutting fluid namely, straight oils, soluble oils,
synthetic and semi synthetic are widely used in metal cutting processes. Bio-based cutting fluids
have the potential to reduce the waste treatment cost due to their inherently higher
biodegradability and may reduce the occupational health risks associated with petroleum-oil-
based cutting fluids since they have lower toxicity. The output is a healthier and cleaner in the
work environment, with less mist in the air. AISI 316L stainless steel work pieces were
machined with drilling, core drilling, reaming and tapping using HSS-E tools. From the
comparison of performance results obtained from two cutting fluids showed that the vegetable
based cutting oils were than the commercial mineral oil. It was an oil-in water emulsion type
which contained a surfactant mixture (Tween 85 and page 400, Merck), and various additives in
the formula to meet the specifications such as resistance to bacterial growth, corrosion,
antifoaming agent and anti wear.
Ezugwu, Lai (1995) show a large amount of heat is created in dry machining because of rubbing
between cutting tool and work piece interface. Dry machining has not fully established itself in
drilling technology, mainly because of extremely high thermal load on the drilling tools resulting
in accelerated tool wear and unsatisfying overall process stability. The optimization of cutting
conditions to make them more suitable for cutting is done through the increase of feed and
decrease of cutting speed. With this roughly the same amount of heat is generated, but the area of
the tool which receives this heat is bigger, making the temperature lower and the amount of chip


10

removed per minute constant. In dry drilling, the drilling tool has to withstand harsh
environment conditions, including high temperatures, frictional forces and large mechanical and
thermal loads [Eyup Bagci, Babul 2006].
Vagnorius & Sorby(2010) found out the effect of high pressure cooling on the tool life in
machining of income 718. They have performed facing operation with speed, 300m/min; feed
rate,0.2 mm/rev; depth of cut,1mm and coolant, emulsion 4%. They have used high pressure of
20 Mpa for high cooling. They claimed that high pressure cooling is very effective when
machining with carbide insists and enhance the tool life and improve the chip breaking ability.
The drawback of this cooling process is to reduce the tool life of ceramics in machining of heat
resistant alloy which occurs due to accelerated notch wear. In this operation, SiAlON ceramic
inserts with improved resistance to notching were tested in machining of Inconel 718 under high
pressure cooling. Then the result is compared to conventional cooling. It is seen that when high
pressure cooling is used notch wear increases slightly which is no longer critical for tool life. On
the other hand, flank wears reduces significantly which leads to longer tool life. They also
showed that when high pressure cooling is used properly it increases the productivity in
machining of heat resistant alloy with ceramics tool.

Adler et al. (2002) explain that cutting fluids have been widely used in machining operations in
efforts to increase cooling and lubricity, and as a result enhance tool life, reduce process
variability, etc. costs associated with the fluid use often constitute between 7 to 17% of total
production costs, as compared to 4% for tooling costs (King et al., 2001). Fluid related expenses
include the cost of installing a fluid supply system, fluid purchase and system maintenance, and
discarded fluid (waste) treatment. Fluid related cost is large because high production
manufacturing plants frequently utilize several cutting fluids reservoirs. Two relatively resent
strategies focused on reducing fluid use are Minimum Quantity Lubrication (MQL) and dry
machining. There are four primary categories of cutting fluids that differ in terms of thermo
physical properties, common process application, and method of treatment. Soluble oils are
mixtures of oil and water and have increased cooling capabilities over straight oils and offer
some rust protection. Concerns with using soluble oils center upon maintenance issues like
evaporative losses and bacterial growth. Semi synthetics are similar to soluble oils in
performance characteristics, but differ in composition because 30% or less of the total volume of
the concentrate contains inorganic or other compounds that dissolve in water.
Beaubien, Cattaneo (1964) explain the application of cutting fluid during machining operation
reduces cutting zone temperature and increases tool life and acts as lubricant as well. Also Dhar
et al (2004) states that without cooling and lubrication, the chip sticks to the tool and breaks it in
a very short cutting time. It reduces cutting zone temperature either by removing heats as coolant
or reducing the heat generation as lubricant. In addition it serves a practical function as chip-
handling medium [Cassin, Boothroyed (1965)]. On the other hand, the cooling and lubricating
affects of cutting fluid influence each other and diminish with increase in cutting velocity
[Katagawa et al (1997)].
Jian et al(2010) found out the effect of cutting parameters on average surface roughness in the
different cooling/lubrication conditions, including minimal quantity lubrication(MQL),wet and
dry cutting. Orthogonal arrays are applied in the design of experiment, and Ti6Al4V end-milling
experiments are performed on the Daewoo machining center. The white light interferometer is


11

used to obtain the 3D profile of machined surface and is calculated the average surface
roughness values. Then, exponential model and quadratic model are proposed to the
experimental data of surface roughness, respectively. Exponential fit model is employed to
determine the significant cutting parameters on average surface roughness. Quadratic fit model is
used to optimize the cutting parameters when the cutting tool and material removal rate are
given. The optimal average surface roughness is estimated according to the quadratic model.
They found that surface roughness under the MQL cutting condition is the best, while the surface
roughness under dry cutting is the worst. They also found the averages surface roughness
decreased with the increase of cutting time due to the running-in process of cutting tools. Under
different cooling condition average surface roughness was sensitive to the feed per tooth and
axial depth of cut. It is not sensitive to the cutting speed and radial depth of cut. They also
showed that the fit precision of quadratic model is much higher than exponential model.

Nouari et al(2005) investigate the effect of machining parameters and coating on wear in dry
drilling of aluminium alloy. they claimed that the temperature which is generated by friction and
plastic deformation in the tool-chip or tool-work piece interface cause tool wear. They found that
wear is related to cutting speed as temperature is not significant. In low cutting speed tool wear is
not severe as tool wear at high cutting speed. So it is seen that wear is function of cutting speed
and coating material. They have performed the drilling operation under dry condition with
cemented tungsten carbide and HSS tools on AA2024 aluminium alloy. They have used three
cutting speed (25,65 and165 m/min) and a constant feed rate of0.04mm/rev. they showed that
high cutting speed generate significant temperate on the rake face of the tool which is
responsible for high diameter deviation. They claimed that maximum hole diameter deviation
and surface roughness occur due to uncoated tungsten carbide drill. On the other hand minimum
hole diameter deviation and surface roughness occur due to coated tungsten carbide drill. They
result also show that HSS tool is not suitable for dry machining of aluminium 2024 alloy

Alves & Oliveria explains that Cutting fluids are used to reduce the negative effects of the heat
& friction on both tool and work piece. The cutting fluids produce three positive effects in the
process: heat removal elimination, lubrication on the chip-tool interface and chip removal. The
several negative effect have caused in the environment & worker health. On the shop floor, the
machine operators may be affected by the negative effects of the cutting fluids. In order to make
machining process more ecological, the Minimum Quantity Lubrication has been accepted as a
successful near-dry application because of environmentally friendly characteristics. The use of
vegetable oils high performance in machining combined with good environment compatibility
could be achieved. Vegetable oils can even enhance the cutting performance, extend the tool life
and improve the surface finish but have some problems due to inadequate oxidative and high or
low temperature observed in this oil.
Kiocke (1997), Derflinger (1999) explains cutting fluids have dual task of cooling the cutting
surface and flashing chip. In some operations such as drilling, for example, cutting fluid is
important to improve the chips front inside holes, thus preventing drill breakage. They also help
to control cutting-face temperature and this can prolong tool life, improve cut quality, and
positively increase part finish. It has the benefit of a powerful stream that can reach into the
cutting area, provides strong chip removal and in some cases enough pressure to debar [Robert


12

(2004)]. Cutting fluids can reduce coefficient of friction at chip tool interface and thus could
reduce cutting forces and increase tool life to some extent.
Vagnorius & Sorby(2010) found out the effect of high pressure cooling on the tool life in
machining of inconel 718. They have performed facing operation with speed, 300m/min; feed
ate,0.2 mm/rev; depth of cut,1mm and coolant, emulsion 4%. They have used high pressure of 20
Mpa for high cooling. They claimed that high pressure cooling is very effective when machining
with carbide insists and enhance the tool life and improve the chip breaking ability. The
drawback of this cooling process is to reduce the tool life of ceramics in machining of heat
resistant alloy which occurs due to accelerated notch wear. In this operation, SiAlON ceramic
inserts with improved resistance to notching were tested in machining of Inconel 718 under high
pressure cooling. Then the result is compared to conventional cooling. It is seen that when high-
pressure cooling is used notch wear increases slightly which is no longer critical for tool life. On
the other hand, flank wear reduces significantly which leads to longer tool life. They also showed
that when high pressure cooling is used properly it increases the productivity in machining of
heat resistant alloy with ceramics tool.

Hong & Broomer (2000) investigate that Cutting fluids are used in Conventional machining to
extend tool life by reducing tool temperature and the friction between the tool, the chip and the
work piece during cutting. Soluble oils are the most common machining coolant used in
metalworking today (Childers 1994). In the United States there are approximately three-quarters
of a million machine tools that use metal working fluids (American Machinist 1989). Over the
last five years metalworking fluids have become a major focus of the Occupational Safety and
Health Administration (OSHA). Metal working fluids are considered one of the top five
workplace health hazards in the United States (Department of Labor 1995). In 1991 an industrial
study indicates that the highest incidences of skin disorders were found in all industries that
involved potential metal working fluids (Department of Labor 1993). Cryogenic machining,
which uses liquid nitrogen (LN2), as a good coolant and it is considered naturally recycling and
environmentally friendly.
Mazurkiewicz M, Kubala Z, Chow J (1989) investigate in machining, conventional cutting fluid
application fails to penetrate the chip-tool interface and thus cannot remove heat effectively. The
high pressure jet of soluble oil, when applied at the chip-tool interface, could reduce cutting
temperature and improve tool life to certain extent [ Mazurkiewicz M, Kubala Z, Chow J(1989);
Alaxender S A, Varadarajean A S, Philip P K]. MQL is an assistant on the economical front.
MQL consists of a mixture of pressurized air and oil micro droplets applied directly into the
interface between the tool and chips. However, the question of how the lubricants can decrease
the friction under very high temperature and loads is still not answered especially for long
engagements time. MQL machining is nearly equal of often better than the traditional wet
machining in tool life and surface finish when cutting steels and aluminum alloys [Kamata Y,
Obikawa T (2007)].
Lee & Hwang (2010) find out the optimal cutting parameters and theirs effects on surface
roughness and cutting force in turning of AISI 1045 at minimum quantity lubrication (MQL)and
wet conditions. Fractional factorial design and central composite design were used for the
experiment. Cutting force and surface roughness were measured through the external cylindrical
turning based on the experiment plan. the taken data were analyzed by regression model and the


13

verification is performed to confirm the results. by using fractional factorial design they found
that nozzle diameter, feed rate, cutting speed and depth of cut are the parameters which affect the
surface roughness of the MQL turning. They claimed cutting speed and depth of cut show
opposite effects on cutting force and surface roughness. They also claimed that surface
roughness and cutting force in MQL in turning is better than the wet turning process.

Taso (2006) refers to aluminum alloys extraordinarily increase year by year due to the
characteristics of light weight and high strength. Due to harshly adhering and wear, aluminum
alloy likely causes chip welding and build up edge during dry cutting. Therefore, cutting fluid is
frequently used in the cutting the aluminums alloy. The role of cutting fluids in improving the
efficiency of metal cutting has been well known. The properties of cutting fluids are not only
important in cooling and lubricating but affect machining skill, recycling time, toxicity and safe
disposal in the environment.
Hasib et al. explain it is clear from experiment that with the increase in speed and depth of cut
the temperature increases even under mist condition due to increase in energy consumption and
higher metal removal rate. But mist application system is still more effective as compared to dry
and flood conditions. From the experiment it shows that tool wear measured for dry, wet and
mist condition increases with the increase the depth of cut and spindle speed. It is evident that for
mist condition the tool wear is less than flood and dry conditions. The mist application enables
reduction of the turning zone temperature up to 10% to 40% more than conventional methods.s
Nikil Ranjon Dhar, Sumaya Islam, Mohammad Kamruzzaman (2007) showed the experiment
investigation on the role of MQL on cutting temperature, tool wear, surface roughness and
dimensional deviation in turning of AISI-4340 steel at industrial speed-feed combinations by
uncoated carbide insert. Experiments had been carried out by plain turning a 125 mm diameter
and 760 mm long rod or AISI- 4340 steel in a powerful and rigid lathe (Lehmann Machine
Company, USA, 15hp) at different cutting velocities and feeds under dry, wet and MQL
conditions. Form experiment it was found that at fixed feed rate and depth of cut, Chip tool
interface temperature increased with cutting velocity and also average principle flank wear with
machining time and average auxiliary flank wear with machining time increased. In the above
three cases chip tool interface temperature, principle flank wear, average auxiliary flank Wear
were low in MQL conditions than dry and wet conditions. Dimensional accuracy and good
surface finish were also found than dry and wet conditions.









14




CHAPTER-3

MACHINING OPERATION
















15

3.1 Drilling Operation in Dry condition.
If there is no lubricant or other types of coolant have not been used in the machining operation is
known dry machining. The work-piece is punched in definite places. The work-piece is setting
with the radial drill machine. Then a drill bit of 6 mm diameter is loaded with drill chuck. After
that drilling operation is performed in the work-piece. Since the cutting fluid has a harmful effect
on the environment and the health of the operator therefore the dry machining has a most
wonderful topic.
v
Fig 3.1 Drilling Operation in Dry condition.
Advantages of dry machining:
Complete elimination of harmful cutting fluid.
It eliminates cost involved in purchase, storage, handling, utilizing and safe
disposal of the fluid.
Reduction in overall production time and improved working condition.

Disadvantages of dry machining:
The temperature of drill bit is too high.
The chip is continuous so the operator has become risk to safe.
Sometimes drill bit becomes breakdown.
The drill bit angle quickly changed with time.
Because of high temperature work-piece has deformed.
Drilling hole accuracy was not preferable to accept.

3.2 Drilling Operation in MQL condition (Cutting-oil).
When dry cutting is not an option because of its drawbacks and difficult cutting conditions and
wet conditions is not an option because of unfavorable consequences of cutting fluids, minimum
quantity cooling and lubrication may be alternative. The developed MQL system consists of four
major parts. Such as


16

Compressor
Lubricating oil reservoir
Mixing chamber
Final nozzle
Compressor used in this purpose is a pneumatic compressor. In MQL system, air oil mixing in
the basic function of the system. A compressor which is used to supply compressed air to the oil
reservoir and mixing chamber. The lubricating oil passes through due to pressure of compressed
air in the reservoir to the mixing chamber.
So at first cutting oil is loaded into the tank of the MQL systems. Under MQL condition, the
lubricating agent needs to be supplied at high pressure and impinged at high speed through
nozzle tip at the cutting zone. The thin but high velocity stream or MQL was projected in such a
direction so that the coolant could reach as close to the chip-tool and the work-tool interfaces as
possible.
v
Fig 3.2 Drilling Operation in MQL condition (Cutting-oil).

Advantages of Drilling Operation in MQL condition (Cutting-oil).
Quickly heat is removed with time.
The cutting fluid is cheaper than compared to other.
Drilling accuracy better than Dry machining.
Tool wear was reduced.

Disadvantages of Drilling Operation in MQL condition (Cutting-oil).
A temperature reduces lower than Olive-oil lubricant.
For the operator it is harmful to health





17

3.3 Drilling Operation in MQL condition (Olive-oil).
At first Olive-oil is loaded into the tank of the MQL systems. Under MQL condition, the
lubricating agent needs to be supplied at high pressure and impinged at high speed through
nozzle tip at the cutting zone. The thin but high velocity stream or MQL was projected in such a
direction so that the coolant could reach as close to the chip-tool and the work-tool interfaces as
possible.

Fig 3.3 Drilling Operation in MQL condition (Olive-oil).

Advantages of Drilling Operation in MQL condition (Olive-oil).
Quickly heat is removed with time.
Drilling accuracy better than Dry machining.
Tool wear was reduced.

Disadvantages of Drilling Operation in MQL condition (Cutting-oil).
A temperature reduces higher than Cutting-oil lubricant.
For the operator it is harmful to health
The cost of Olive-oil is high.







18



CHAPTER-4

EXPERIMENTAL INVESTIGATION




















19

4.1 Introduction
Drilling metals by high speed steel (HSS) is a major activity in the manufacturing industries.
Drilling of steels involves more heat generated for their ductility and production of continuous
chips having more intimate and wide chip-tool contact. The commonly used steel like AISI-1040
steel has been undertaken for the present investigations. Considering common interest and time
constraint, only HSS drill bits have been used in present investigation. Wide scope will remain
for further study on cutting fluids effect in drilling steels by HSS and exotic materials by high
performance drill bit. The drilling test were carried out by drilling of AISI-1040 steel on the
Radial drill machine (RM-U9 Radial Drill Machine, Sweden) by HSS drill under MQL
conditions. Previously this same work was carried out but under dry, wet and MQL conditions.
Now investigate by using two lubricants (Cutting-oil, Olive-oil) in MQL conditions and also
compare with Dry machining and find what lubrication will be more preferable under the basis
of hole accuracy & chips morphology.
4.2 Experimental conditions
Table 4.2.1 Experimental condition of Dry Machining.
Machine Tool RM-U, Radial Drill Machine, Sweden, 1.5 KW
Work Material AISI-1040 [C-0.40%, Plain Carbon Steel]
Cutting Tool High Speed Steel(HSS), Diameter 8 mm
Process Parameters
Cutting speed
Feed rate
Depth of cut

440 rpm
0.16 mm/rev.
19.5 mm
Cutting fluid supply 1.2 litter/min
Environment Dry condition

Table 4.2.2 Experimental condition of MQL Machining (Olive-oil & Cutting-oil).
Machine Tool RM-U, Radial Drill Machine, Swedens, 1.5
KW
Work Material AISI-1040 [C-0.40%, Plain Carbon Steel]
Cutting Tool High Speed Steel(HSS), Diameter 8 mm
Process Parameters
Cutting speed
Feed rate
Depth of cut

440 rpm
0.16 mm/rev.
19.5 mm
Cutting fluid supply 200ml/hr, Air 4 bar
Environment MQL condition



20

4.3 Data & Calculations
4.3.1 Dry Condition
Table 4.3.1 Diameter of holes under Dry condition at 440 rpm (Drill bit dia.-8mm).
No. of holes Drilled hole dia. Close to
beginning of the hole (mm)
Drilled hole dia. Close to
end of the hole (mm)
Deviation
01 8.29 8.00 0.29
02 8.36 8.05 0.31
03 8.46 8.05 0.41
04 8.49 8.09 0.40
05 8.37 8.01 0.36
06 8.48 8.02 0.46
07 8.44 8.03 0.41
08 8.32 8.01 0.31
09 8.49 8.10 0.39
10 8.40 8.02 0.38

Standard Deviation =

2
K= No. of holes

= Means of K data.

=

Means of drilled hole dia. Close to beginning of the hole (mm)
=

= 8.41
Standard deviation of drilled hole dia. Close to beginning of the hole (mm)

=0.5311 = =0.72877



21

Means of drilled hole dia. Close to end of the hole (mm)

= 8.038
Standard deviation of drilled hole dia. Close to end of the hole (mm)

= 0.001773 = = 0.03425


Fig 4.3.1 Line of deviation in the Dry condition.

0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
1 2 3 4 5 6 7 8 9 10
D
e
v
i
a
t
i
o
n

(Dry condition)


22


Fig 4.3.2 Bar chart of the deviation in Dry condition.


4.3.2 MQL Condition (Cutting-oil).
Table 4.3.2 Diameter of holes under MQL condition (Cutting-oil) at 440 rpm (Drill bit dia.-
8mm).
No. of holes Drilled hole dia. Close to
beginning of the hole (mm)
Drilled hole dia. Close to
end of the hole (mm)
Deviation
01 8.24 8.02 0.22
02 8.31 8.03 0.28
03 8.26 8.01 0.25
04 8.28 8.07 0.21
05 8.3 8.04 0.26
06 8.25 8.05 0.2
07 8.22 8.04 0.18
08 8.31 8.03 0.28
09 8.28 8.04 0.22
10 8.25 8.02 0.23




0
0.1
0.2
0.3
0.4
0.5
1 2 3 4 5 6 7 8 9 10
D
e
v
i
a
t
i
o
n

No of holes
(Dry condition)


23

Standard Deviation =

2
K= No. of holes

= Means of K data.

=

Means of drilled hole dia. Close to beginning of the hole (mm)
=

= 8.27
Standard deviation of drilled hole dia. Close to beginning of the hole (mm)

=0.0009556 = =0.030912


Means of drilled hole dia. Close to end of the hole (mm)

= 8.035
Standard deviation of drilled hole dia. Close to end of the hole (mm)

= 0.0002944 = = 0.017159



24


Fig 4.3.3 Line of deviation in the MQL (Cutting-oil) condition.





Fig 4.3.4 Bar chart of the deviation in MQL (Cutting-oil) condition.

1 2 3 4 5 6 7 8 9 10
Cutting-oil 0.22 0.28 0.25 0.21 0.26 0.2 0.18 0.28 0.22 0.23
0
0.05
0.1
0.15
0.2
0.25
0.3
D
e
v
i
a
t
i
o
n

Cutting-oil
0
0.05
0.1
0.15
0.2
0.25
0.3
1 2 3 4 5 6 7 8 9 10
Cutting-oil 0.22 0.28 0.25 0.21 0.26 0.2 0.18 0.28 0.22 0.23
D
e
v
i
a
t
i
o
n

Cutting-oil


25

4.3.4 MQL Condition (Olive-oil)
Table 4.3.3 Diameter of holes under MQL condition (Olive-oil) at 440 rpm (Drill bit dia.-8mm).

No. of holes Drilled hole dia. Close to
beginning of the hole (mm)
Drilled hole dia. Close
to end of the hole (mm)
Deviation
01 8.24 8.01 0.23
02 8.22 8.02 0.2
03 8.26 8.02 0.24
04 8.23 8.01 0.22
05 8.27 8.05 0.22
06 8.29 8.05 0.24
07 8.3 8.04 0.26
08 8.28 8.03 0.25
09 8.22 8.01 0.21
10 8.25 8.03 0.22

Standard Deviation =

2
K= No. of holes

= Means of K data.

=

Means of drilled hole dia. Close to beginning of the hole (mm)
=

= 8.25
Standard deviation of drilled hole dia. Close to beginning of the hole (mm)

=0.0008266 = = 0.028752



26


Means of drilled hole dia. Close to end of the hole (mm)

= 8.02
Standard deviation of drilled hole dia. Close to end of the hole (mm)

= 0.0002455 = = 0.01567



Fig 4.3.5 Bar chart of the deviation in MQL (Olive-oil) condition
0
0.05
0.1
0.15
0.2
0.25
0.3
1 2 3 4 5 6 7 8 9 10
Olive-oil 0.23 0.2 0.24 0.22 0.22 0.24 0.26 0.25 0.21 0.22
D
e
v
i
a
t
i
o
n

Olive-oil


27


Fig 4.3.6 Line of the deviation in MQL (Olive-oil) condition

Table 4.3.4 Data of these three Lubrication systems.
RPM Lubrication
System
Diameter close to beginning of the
hole (mm)

Diameter close to end of the
hole (mm)

D
max


D
min



D
ave



Standard
deviation


D
max


D
min



D
ave



Standard
deviation

440 Dry 8.49 8.29 8.39 0.7287 8.09 8.00 8.04 0.03425
440 MQL(Cutting-oil) 8.31 8.22 8.26 0.030912 8.07 8.01 8.04 0.017159
440 MQL(Olive-oil) 8.30 8.22 8.26 0.028752 8.05 8.01 8.03 0.01567









1 2 3 4 5 6 7 8 9 10
Olive-oil 0.23 0.2 0.24 0.22 0.22 0.24 0.26 0.25 0.21 0.22
0
0.05
0.1
0.15
0.2
0.25
0.3
D
e
v
i
a
t
i
o
n

Olive-oil


28

4.4 Comparison of Deviation with each other
4.4.1 Dry condition & MQL (Cutting-oil).


Fig 4.4.1Bar chart of Comparison of deviation within Dry & Cutting-oil conditions


Fig 4.4.2 Line of Comparison of deviation within Dry & Cutting-oil conditions

0
0.1
0.2
0.3
0.4
0.5
1 2 3 4 5 6 7 8 9 10
Dry 0.29 0.31 0.41 0.4 0.36 0.46 0.41 0.31 0.39 0.38
Cutting-oil 0.22 0.28 0.25 0.21 0.26 0.2 0.18 0.28 0.22 0.23
D
e
v
i
a
t
i
o
n

Dry/Cutting-oil
1 2 3 4 5 6 7 8 9 10
Dry 0.29 0.31 0.41 0.4 0.36 0.46 0.41 0.31 0.39 0.38
Cutting-oil 0.22 0.28 0.25 0.21 0.26 0.2 0.18 0.28 0.22 0.23
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
D
e
v
i
a
t
i
o
n

Dry/Cutting-oil


29

4.4.2 Dry Condition & MQL (Olive-oil).

Fig 4.4.3 Bar chart of Comparison of deviation within Dry & Olive-oil conditions



Fig 4.4.4 Line of Comparison of deviation within Dry & Olive-oil conditions


0
0.1
0.2
0.3
0.4
0.5
1 2 3 4 5 6 7 8 9 10
Olive-oil 0.23 0.2 0.24 0.22 0.22 0.24 0.26 0.25 0.21 0.22
Dry 0.29 0.31 0.41 0.4 0.36 0.46 0.41 0.31 0.39 0.38
D
e
v
i
a
t
i
o
n

Dry/Olive-oil
1 2 3 4 5 6 7 8 9 10
Olive-oil 0.23 0.2 0.24 0.22 0.22 0.24 0.26 0.25 0.21 0.22
Dry 0.29 0.31 0.41 0.4 0.36 0.46 0.41 0.31 0.39 0.38
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
D
e
v
i
a
t
i
o
n

Dry/Oive-oil


30

4.4.3 Olive-oil & Cutting-oil

Fig 4.4.5 Bar chart of Comparison of deviation within Cutting-oil & Olive-oil conditions



Fig 4.4.6 Line of Comparison of deviation within Cutting-oil & Olive-oil conditions


0
0.05
0.1
0.15
0.2
0.25
0.3
1 2 3 4 5 6 7 8 9 10
Cutting-oil 0.22 0.28 0.25 0.21 0.26 0.2 0.18 0.28 0.22 0.23
Olive-oil 0.23 0.2 0.24 0.22 0.22 0.24 0.26 0.25 0.21 0.22
D
e
v
i
a
t
i
o
n

Cutting-oil/Olive-oil
1 2 3 4 5 6 7 8 9 10
Cutting-oil 0.22 0.28 0.25 0.21 0.26 0.2 0.18 0.28 0.22 0.23
Olive-oil 0.23 0.2 0.24 0.22 0.22 0.24 0.26 0.25 0.21 0.22
0
0.05
0.1
0.15
0.2
0.25
0.3
D
e
v
i
a
t
i
o
n

Cutting-oil/Olive-oil


31

4.4.4 Three Lubrication (Dry, Cutting-oil, Olive-oil).


Fig 4.4.7 Bar chart of Comparison of deviation within Cutting-oil, Dry & Olive-oil conditions.


Fig 4.4.7 Line of Comparison of deviation within Cutting-oil, Dry & Olive-oil conditions.



0
0.1
0.2
0.3
0.4
0.5
1 2 3 4 5 6 7 8 9 10
Cutting-oil/Olive-oil/Dry
Cutting-oil
Olive-oil
Dry
1 2 3 4 5 6 7 8 9 10
Cutting-oil 0.22 0.28 0.25 0.21 0.26 0.2 0.18 0.28 0.22 0.23
Olive-oil 0.23 0.2 0.24 0.22 0.22 0.24 0.26 0.25 0.21 0.22
Dry 0.29 0.31 0.41 0.4 0.36 0.46 0.41 0.31 0.39 0.38
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
D
e
v
i
a
t
i
o
n

Cutting-oil/Olive-oil/Dry


32

4.4.5 Comparison of standard deviation beginning of the hole.

Fig 4.4.8 Bar chart of Comparison of standard deviation within Cutting-oil, Dry & Olive-oil
conditions at the beginning of the hole.



Fig 4.4.9 Line of Comparison of standard deviation within Cutting-oil, Dry & Olive-oil
conditions at the beginning of the hole

0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Dry Cutting-oil Olive-oil
S
t
a
n
d
e
r
d

d
e
v
i
a
t
i
o
n

Dry/Cutting-oil/Olive-oil
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Dry Cutting-oil Olive-oil
S
t
a
n
d
e
r
d

D
e
v
i
a
t
i
o
n

Dry/Cutting-oil/Olive-oil



33

4.4.6 Comparison of standard deviation end of the hole.

Fig 4.4.10 Bar chart of Comparison of standard deviation within Cutting-oil, Dry & Olive-oil
conditions at the end of the hole.


Fig 4.4.11 Line of Comparison of standard deviation within Cutting-oil, Dry & Olive-oil
conditions at the end of the hole.


0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
Dry Cutting-oil Olive-oil
S
t
a
n
d
e
r
d

d
e
v
i
a
t
i
o
n

Dry/Cutting-oil/Olive-oil

0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
Dry Cutting-oil Olive-oil
S
t
a
n
d
e
r
d

d
e
v
i
a
t
i
o
n

Dry/Cutting-oil/Olive-oil


34

4.4.7 Comparison of diameter beginning of the hole.


Fig 4.4.12 Bar chart of Comparison of diameter within Cutting-oil & Dry conditions at the
beginning of the hole.



Fig 4.4.13 Bar chart of Comparison of diameter within Cutting-oil & Olive-oil conditions at the
beginning of the hole.
8.05
8.1
8.15
8.2
8.25
8.3
8.35
8.4
8.45
8.5
1 2 3 4 5 6 7 8 9 10
Dry/Cutting-oil
Dry Cutting-oil
8.16
8.18
8.2
8.22
8.24
8.26
8.28
8.3
8.32
1 2 3 4 5 6 7 8 9 10
Cutting-oil/Olive-oil
Cutting-oil Olive-oil


35



Fig 4.4.14 Bar chart of Comparison of diameter within Dry, Cutting-oil & Olive-oil conditions at
the beginning of the hole.

4.4.8 Comparison of diameter end of the hole.

Fig 4.4.15 Bar chart of Comparison of diameter within Cutting-oil & Dry conditions at the end of
the hole.
8.05
8.1
8.15
8.2
8.25
8.3
8.35
8.4
8.45
8.5
1 2 3 4 5 6 7 8 9 10
Dry/Cutting-oil/Olive-oil
Dry Cutting-oil Olive-oil
7.94
7.96
7.98
8
8.02
8.04
8.06
8.08
8.1
1 2 3 4 5 6 7 8 9 10
Dry
Cutting-oil


36


Fig 4.4.16 Bar chart of Comparison of diameter within Cutting-oil & Dry conditions at the end of
the hole.


Fig 4.4.17 Bar chart of Comparison of diameter within Dry, Cutting-oil & Olive-oil conditions at
the end of the hole.



7.98
7.99
8
8.01
8.02
8.03
8.04
8.05
8.06
8.07
1 2 3 4 5 6 7 8 9 10
Cutting-oil
Olive-oil
7.94
7.96
7.98
8
8.02
8.04
8.06
8.08
8.1
1 2 3 4 5 6 7 8 9 10
Dry
Cutting-oil
Olive-oil


37

4.5 Chips Morphology
In the experiment, the drilling chips were investigated. From the chip morphology, the quality of
different types of chips for different conditions shows a great concept about the contribution of
lubrication systems.

Fig4.5.1: Photographic view of Chips while drilled AISI-1040 Steel under Dry condition at 440
rpm (8 mm drill bit).

Fig4.5.2: Photographic view of Chips while drilled AISI-1040 Steel under MQL (Cutting-oil)
condition at 440 rpm (8 mm drill bit).

Fig4.5.3: Photographic view of Chips while drilled AISI-1040 Steel under MQL (Olive-oil)
condition at 440 rpm (8 mm drill bit).



38




CHAPTER-5

RESULT & DISCUSSION










39

5.1 Result & Discussion
5.1.1 Roundness Deviation
From Fig 4.4.1 & Fig 4.4.2 Comparison of deviation within Dry & Cutting-oil conditions
we see that the roundness deviation of Dry condition always higher than Cutting-oil
condition.
From Fig 4.4.3 & Fig 4.4.4 Comparison of deviation within Dry & Olive-oil conditions
we see that the roundness deviation of Dry condition always higher than Olive-oil
condition
From Fig 4.4.5 & Fig 4.4.6 Comparison of deviation within Cutting-oil & Olive-oil
conditions we see that the roundness deviation of Cutting condition always higher than
Olive-oil condition
From Fig 4.4.7 & Fig 4.4.8 Comparison of deviation within Cutting-oil, Dry & Olive-oil
conditions. We see that the roundness deviation of among Cutting-oil, Olive-oil & Dry
conditions, the deviation of Olive-oil is the minimum position contains.
Finally we told that the deviation of MQL (Olive-oil) conditions is the lowest value of
these three lubrication environment.
5.1.2 Chips morphology
In the experiment, the drilling chips were investigated. From the chip morphology, the quality of
different types of chips for different conditions shows a great concept about the contribution of
lubrication systems.
Dry condition
The shape of chips in dry condition is spiral & continuous. Since in drilling the cutting zone
temperature become highly heated. For continuous chips the operator has risk and also the drill bit
hampered.
MQL (Cutting-oil) condition
The shape of chips became string and discontinuous. Since cutting zone temperature reduces than dry
condition. The color of chips became metallic from burnt blue due to reduction in temperature. So it
increased tool life.
MQL (Olive-oil) condition
The chips were smooth have no build up edges and chips size is lamellar but small in size.
Finally we told that the chips of Olive-oil conditions are preferable to work-piece & tool life.




40


CHAPTER-6

CONCLUSIONS &
RECOMMENDATION




















41

6.1 Conclusions
After completing the drilling operation in the three conditions of AISI-1040 steels we can
summarize the following:
Roundness deviation of MQL (Olive-oil) conditions was smaller than Dry & MQL
(Cutting-oil) conditions.
The formation of chips under MQL (Olive-oil) conditions more favorable compared to
Dry & MQL (Cutting-oil) conditions.
Among Dry, MQL (Olive-oil) & MQL (Cutting-oil), the Olive-oil lubrication is the best
to the work-piece & tool life.
6.2. Further recommendation
For future work we suggest the use of cryogenic coolant for machining operation
At a low rate i.e.10 ml/hr can be applied in MQL systems.
Highly update radial drill machine can be used to operation.

6.3 Limitations
The drilling machine in our machine shop is ancient.
The MQL set up was not quite accurate.
The MQL application was not perfectly.
The drill bit was not accurate in operation in the time of every drill.












42


6.4 References
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43

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14. Nikhil Ranjan Dhar, Sumaiya Islam, Mohammad Kamruzzamn,Effect of Minimum
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15. Matthew Bono, Jun Ni, The Location of the Maximum Temperature on the cutting
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21. Kamata Y, Obikawa T, High speed MQL Finish Turning of Inconel 718 with Coated
Tools, Journal of Materials Processing Technology, 191-193 (2007), 251-256.

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Layer Selected Properties, Journal of POLISH CIMAC (2007).



44

23. Sanjay, C, Neemab M L, Chin C W, Modeling of Tool Wear in Drilling by Statistical
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26. Dibag S, Rao P V, (2007), Performance improvement of hard turning with solid
lubricants. International Journal Advance Manufacturing Technology (2008),pp.275-
281.


27. Litvinov L P, Vibration-assisted Drilling of Deep Holes, Soviet Engineering Research,
Vol.10 (5) (1990), pp. 5-8.

28. Diniz A E, (2007), Hard turning of interrupted surfaces using CNB tools. Journal of
Materials Processing Technology 195 (2008) pp. 275-281.

29. Chiffre L D, Belluco W, Investigations of cutting fluids performance using different
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45