GENERAL ARTICLES

 

Investigating of eco- and energy-efficient lubrication strategies for the drilling of light metal alloys

 

 

N.F. Treurnicht^I; H.J. Joubert^II; G.A. Oosthuizen^III; G. Akdogan^IV

^IDepartment of Industrial Engineering, University of Stellenbosch, South Africa nicotr@sun.ac.za
^IIDepartment of Industrial Engineering, University of Stellenbosch, South Africa h2j@sun.ac.za
^IIIDepartment of Industrial Engineering, University of Stellenbosch, South Africa tiaan@sun.ac.za
^IVDepartment of Industrial Engineering, University of Stellenbosch, South Africa gakdogan@sun.ac.za

 

 

---

ABSTRACT

Energy use will be one of the main drivers for the achievement of more eco-efficient drilling processes in the automotive industry. Industry awareness of the environmental impact of used cutting emulsions, and the negative effect on worker health, has increased sharply. This has led to innovative lubrication methods such as through-spindle minimal quantity lubrication (MQL) for drilling aluminium-silicon alloys. In this work the performance of MQL at different cutting speeds and feed rates has been investigated using infrared temperature measurements. The results indicate that MQL is a feasible eco-efficient alternative to conventional flood cooling when drilling aluminium-silicon alloys.

---

OPSOMMING

Energiebenutting maak een van die hoofdryfvere uit om eko-doeltreffendheid te behaal in boorprosesse in die motornywerheid. Nywerheidsbewustheid van die omgewingsimpak van gebruikte sny-vloeistowwe, en die negatiewe effek daarvan op werkergesondheid, het skerp toegeneem. Hierdie bewustheid het aanleiding gegee tot die ontwikkeling van smeringsmetodes soos deur-spil minimale hoeveelheid smering (Engels: Minimal Quantity Lubrication, MQL) vir die boor van aluminium-silikon legerings. In hierdie werk word die prestasie van MQL ondersoek teen verskillende snyspoed- en voertempo-kondisies deur middel van infra-rooi temperatuurmeting. Die resultate dui daarop dat MQL 'n lewensvatbare eko-vriendelike alternatief tot konvensionele vloedverkoeling is, wanneer aluminium-silikon legerings geboor word.

---

 

 

“Full text available only in PDF format”

 

 

 

REFERENCES

[1] Byrne, G., Dornfeld, D. & Denkena B. 2003. Advancing cutting technology. Keynote papers STC "C". Annals of CIRP, 52(2), pp 483-508.         [ Links ]

[2] Klocke, F. and Arntz, K. 2010. Advancing manufacturing technologies - enablers for efficient products. COMA International Conference on Competitve Manufacturing, Stellenbosch, South Africa, pp 3-6.         [ Links ]

[3] Dhar, N.R., Kamruzzaman, M. & Ahmed, M. 2006. Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AlSl-4340 steel. Journal of Materials Processing Technology, 172 (2), pp 299-304.         [ Links ]

[4] Itoigawa, F., Childs, T., Nakamuraa, T. & Belluco, W. 2006. Effects and mechanisms in minimal quantity lubrication machining of an aluminum alloy. Wear, 260, pp 339-344.         [ Links ]

[5] Bragaa, D., Dinizc, A., Miranda, G. & Coppini, N. 2002. Using a minimum quantity of lubricant (MQL) and a diamond coated tool in the drilling of aluminum-silicon alloys, Journal of Materials Processing Technology, 122, 127-138.         [ Links ]

[6] Sreejith, P.S. & Ngoi, B.K.A. 2000. Dry machining: Machining the future. Journal of Materials Processing Technology, 101 (1), pp 287-291.         [ Links ]

[7] Byrne, G. & Scholta, E. 1993. Environmentally clean machining processes - a strategic approach. Annals of the CIRP, 42 (1), pp 471-474.         [ Links ]

[8] Sokovic, M. & Mijanovic, K. 2001. Ecological aspects of the cutting fluids and its influence on quantifiable parameters of the cutting processes. Journal of Materials Processing Technology, 109 (1-2), pp 181-189.         [ Links ]

[9] Klocke, .F 1997. Dry cutting. Annals of the CIRP, 1997, 46 (2), pp 519-526.         [ Links ]

[10] Derflinger, V., Brändle, H. & Zimmermann, H. 1996. New hard/ lubricant coating for dry machining. Journal of Surface Coating Technology, 113, pp 286-292.         [ Links ]

[11] Neugebauer, R., Blau, P., Harzbecker, C. & Weilich, D. 2008. Ressourceneffiziente Maschinen- und Prozessgestaltung. CPK 2008: Chemnitzer Produktionstechnisches Kolloquiu, Chemnitz, Germany: Fraunhofer Institut Werkzeugmaschinen und Umformtechnik, pp 49-67.         [ Links ]

[12] Sato, M., Ueda, T. & Tanaka, H. 2007. An experimental technique for the measurement of temperature on CBN tool face in end milling. International Journal of Machine Tools and Manufacturing, 47 (14), pp 2071-2076.         [ Links ]

[13] Ezugwu, E.O. & Wang, Z.M. 1997. Titanium alloys and their machininability - a review, Journal of Materials Processing Technology, 68 (3), pp 262-274.         [ Links ]

[14] Leskover, P. & Grum, J. 1986. The metallurgical aspect of machining. Annals of CIRP, 35 (1), pp 537-550.         [ Links ]

[15] Tönshoff, H.K. & Brinksmeier, E. 1986. Determination of the mechanical and thermal influences on machined surface by microhardness and residual stress analysis. Annals of CIRP, 29 (2), pp 519-532.         [ Links ]

[16] Su, Y., He, N., Li, L. & Li, X.L. 2006. An experimental investigation of effects of cooling/lubrication conditions on tool wear in high-speed end milling of Ti-6Al-4V. Wear, 261 (7-8), pp 760-766.         [ Links ]

[17] Moufki, A., Molinari, A. & Dudzinski, D. 1998. Modelling of orthogonal cutting with a temperature dependent friction law. Journal of Mechanics and Physics of Solids, 46, pp 2103-2138.         [ Links ]

[18] Nouari, M., List, G., Girot, F. & Ge'hin, D. 2005. Effect of machining parameters and coating on wear mechanisms in dry drilling of Al alloys. International Journal of Machine Tools and Manufacturing, 45 (12-13), pp 1436-1442.         [ Links ]

[19] Sandvik Coromant (Pty) Ltd, Sandvik Metalcutting Technical Guide, 2005, E 54. 38        [ Links ]

 

 

* Corresponding author.
1 The author was enrolled for an PhD (Industrial) degree in the Department of Industrial Engineering, University of Stellenbosch.
2 The author was enrolled for an MSc Eng (Industrial) degree in the Department of Industrial Engineering, University of Stellenbosch.
3 The author was enrolled for an PhD (Industrial) degree in the Department of Industrial Engineering, University of Stellenbosch.