David Alan Stephenson

Dry and minimum quantity lubrication high-throughput drilling of compacted graphite iron

ABSTRACT This research studies the sustainable and high-throughput drilling of compacted graphite iron (CGI), a high strength, lightweight material for automotive powertrain applications. CGI drilling experiments were conducted using a 4 mm diameter coated carbide drill at 26.5 mm/s feed rate. In two repeated tests under three lubrication conditions: dry, dry with through-the-drill compressed air, and through-the-drill minimum quantity lubrication (MQL), the drills were able to produce a maximum of 1,740, 3,150 and 2,948 holes, respectively, before the breakage of the drill. The Joule–Thomson effect due to the expansion of high pressure air from through-the-drill holes at the drill tip, chip shape, chip size and chip speed are investigated. Flank wear of the drill cutting edge is measured and results are correlated to drill life. Results indicate that dry machining of CGI is technically feasible. Chip evacuation and advanced tool cooling are important factors that affect drill life for high-throughput sustainable dry drilling of CGI.