1.2.

Literature review
This paper [7] reports on the effect of different lubricanting environments when 6061 aluminium
alloy is machined with diamond-coated carbide tools. The effect of dry machining, minimum
quantity of lubricant (MQL), and flooded coolant conditions was analyzed with respect to the
cutting forces, surface roughness of the machined work-piece and tool wear. The three types of
coolant environments were compared.
This paper [8] reports that dry drilling of aluminium alloys (without using cutting fluids) is an
environmentally friendly machining process but also an exceedingly difficult task due to
aluminiums tendency to adhere to the drills made of conventional materials such as the highspeed steel (HSS). Diamond-like carbon (DLC) coatings improve the dry drilling performance due
to their adhesion mitigating properties. In this work, improvements that are possible when DLC
coated tools are used under minimum quantity lubrication (MQL) condition in drilling of an Al
6%Si (319 Al) alloy were examined. Results were compared with drilling using conventional
flooded coolant. The experimental approach consisted of the evaluation of the cutting performance
of DLC coated HSS drills in a distilled water spray (30 ml/h) used as the MQL agent. Two types
of DLCs (non-hydrogenated and hydrogenated) with different tribological responses in H2O
testing environment were considered. The H2O-MQL cutting of 319 Al using either type of DLC
coated drills reduced the drilling torque compared to dry drilling to a level similar to the
performance under the flooded condition. An added advantage of the H2O-MQL over dry drilling
was that the process was more stable; a smaller percentage of drilled holes exhibited torque
spikes, i.e., an abrupt increase in torque, indicative of adhesion. H2O-MQL cutting using nonhydrogenated DLC was preferred to hydrogenate DLC because it resulted in smaller built-up edge
(BUE) formation and also less amount of drill flute aluminium adhesion resulting in less torque
and thrust force being required during drilling.
This paper [2] reported that the improvement in the coatings of carbide tools and in the chemical
and mechanical properties of tool materials, has caused the increase of tool working life in
machining processes. This fact has allowed the use of the so-called dry machining technology and
also machining with minimal quantity of lubricant. There are many important factors that justify
the development of such technologies, including the high costs of refrigeration, the ecological
damages caused by the use of lubricants, the increasing law demands, related to the preservation
of the environment, workers health, etc. The main objective of this work is to compare the
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performance of the uncoated and diamond coated carbide drills, using minimal lubrication (10
ml/h of oil in a flow of compressed air) and abundant soluble oil as a refrigerant/lubricant in the
drilling of aluminumsilicon alloys (A356).
This paper [3] discusses the experimental characterization of the micro-drilling process with the
nano fluid minimum quantity lubrication (MQL). The miniaturized drilling machine tool system
is developed, and then a series of micro-drilling experiments are conducted in the cases of
compressed air lubrication, pure MQL and nano-fluid MQL for the nano fluid MQL, nanodiamond particles having the diameter of 30 nm are used with the base fluids of paraffin and
vegetable oils. For the micro-drilling process, an uncoated carbide twist drill having the diameter
of 200 mm is used for making holes in the aluminum 6061 workpiece. The experimental results
show that the nano fluid MQL significantly increases the number of drilled holes and reduces the
drilling torques and thrust forces. In addition, the nano fluid MQL effectively eliminates remaining
chip sand burrs to enhance the quality of drilled holes.
This journal paper [4] reported that the main objective was to study the potency of MQL palm oil
(MQLPO) as a lubricant in the high speed drilling of Ti6Al4V. For the comparison, MQL
synthetic ester (MQLSE), air blow and flood conditions were selected. Uniform flank wear, microchipping, thermal cracking and flaking were the dominant tool failure modes. It was found that
MQLSE and MQLPO gave comparable performance with the flood conditions. In addition,
MQLPO outperformed MQLSE on the cutting forces, temperature, power and specific cutting
energy. This shows that palm oil can be used as a viable alternative to synthetic ester for MQL
lubricant.
This paper [5] presents a study of the temperature reached during drilling of the titanium alloy
Ti6Al4V, employing class K10 carbide drills with and without hard coating (TiAlN, CrCN or
TiCN). The main object of this study was to evaluate the temperature for different coated tools
under the condition of application of minimal quantity of lubricant (MQL). The drilling process
was chosen to evaluate the effect of the lubrication obtained with MQL, where the lubricant was
applied either with an external nozzle or internally through the drill. The results show potential for
drilling with MQL applied internally through the tool. For drilling with MQL applied with an
external nozzle, the process was restricted to small depths and limited with reference to the
requirements of the surface quality of the hole.

This paper [6] reported that the deep hole drilling process with solid carbide twist drills is an
efficient alternative to the classic single-lip deep hole drilling, due to the generally higher feed
rates possible and the consequently higher productivity. Furthermore the minimum quantity
lubrication (MQL) can be applied, in order to reduce the production costs and implement an
environmentally friendly process. Because of the significantly reduced cooling performance when
using MQL, a higher heat loading results for the tool and the workpiece. This paper presents the
investigations of the temperature distribution in the workpiece and the heat balance of the deep
hole drilling process. From the paper [1] presented the drilling of deep and small boreholes using
twist drills has to be considered as one of the most difficult metal cutting operations. There are
many reasons for this, one of them being that the cutting fluid has to be supplied externally. This
research work investigates in how far the manner of supplying and the type of minimum quantity
lubricant have an effect on the tool life of coated and uncoated high-speed steel twist drills of 1.5
mm diameter. Deep-hole drilling is performed as the holes, drilled into plain carbon steel, had a
depth of 10 times the diameter. The feasibility of dry machining as an appropriate alternative to
MQL in deep-hole drilling has also been investigated. This work shows that, compared to a
continuous supply of the minimum quantity lubricant, a discontinuous supply brings about a
significant reduction in tool life, especially in the case of heat-sensitive drills. With respect to the
type of minimum quantity lubricant, a low-viscous type with a high cooling capability gave rise to
a notably prolonged tool life. It is also shown that dry drilling is associated with strongly
accelerated tool wear for most of the twist drills tested, resulting in a significant reduction in tool
life.
This paper [9] shows that in machining, coolants and lubricants improve machinability, increase
productivity by reducing the tool wear and extend the tool life. However, the use of cutting fluids
in metal working operations may seriously degrade the quality of the environment. Consequently,
many governments recommend the manufacturers to reduce the volume and the toxicity of their
cutting fluids. Up to now, dry machining has remained a real challenge for the industrial world,
particularly in aerospace engineering. The experimental approach taken in this study resulted in
the development of both optimized tool geometry and optimized cutting conditions for drilling
aluminium alloys without the need for lubrication. The experimental investigations were carried
out with WCCo cemented carbide drills. The use of diamond as coating material allowed to
extend the tool life. The combination of the optimized tool geometry and the cutting conditions
5

entails a high surface quality, a good dimensional accuracy of the machined material and ensures
a long lifetime to the drill. Besides, a numerical calculation with Third Wave Advent Edge TM
finite element software was used to predict the toolchip interface temperature, which is the major
parameter inducing tool wear in dry drilling.

1.3. Knowledge gained from the literature

The lot of research work done in the use of many MQL oil such as SETOL ST-SHAD, SETOL
ST-SHAD20A, SETOA SOE, paraffin and vegetable oil etc. Its improve the machinability
performances in terms of high cutting forces, quality of holes and surface roughness compare to
other lubrication conditions. The dry condition produced a poor result in terms of tool life, high
cutting forces and machining temperature. However, the MQL and flood conditions exhibited
comparable performance in tool life and cutting forces in machining. Adhesion, and abrasion were
the distinct tool wear mechanisms responsible for the formation of failure modes in all coolant
lubricant conditions. In addition MQL improved the intensity of the workpiece adherence on the
cutting tool compared to the dry and flood condition. The amount of chip stuck on the nose of the
tool was responsible for the higher value of feed force, quality of MQL, workpiece material and
depending on tool material used.

1.4. Gaps identified

Based on the available datas from the research papers it was found that surface roughness analysis
was not taken into account for the experimental purpose which was included in our experiment.
Also it was found that surface roughness gets reduced in MQL conditions.

1.5. Objective of project

The main objective of this work is to compare the performance of the HSS tool in dry, minimum
quantity lubrication (80 ml/h of oil in a flow of compressed air) and abundant soluble oil as a
refrigerant/lubricant in the drilling of aluminum alloys (6061). The results showed an irregular
wear in the surface of the HSS drill and a decrease in the quality of the hole made by both dry and
flood condition compared to the MQL condition. Taking into consideration all the conclusions
reached in this work, the most important one is that the performance of the process (in terms of
forces, tool wear, quality of holes and surface roughness), when using minimal lubrication, was
very similar to that obtained when using a high amount of soluble oil, with HSS drills. This
conclusion proves the potential of using this technique in the drilling process of aluminum alloys.

1.6. Motivation
Drilling is the most difficult machining process, it exhibits rapid wear rate of cutting tools due to
high cutting temperature generated during the process. Thus effective control of the heat generated
during machining is essential to ensure good workpiece quality. Cutting fluids are applied to avoid
the problem; however cutting fluids are restricted due to their harmful health and environmental
impacts. Newly developed economical and environmental friendly alternative to completely dry
or flood lubrication is minimum quantity of lubrication (MQL). Cutting fluids are difficult to
dispose and expensive to recycle and can cause skin and lung disease to the operators and air
pollution. Because of the negative effects associated with the cutting fluids and also the stringent
environmental policies, a lot of research has been recently directed towards minimizing the use of
cutting fluids or to totally avoid them. Elimination on the use of cutting fluids, if possible can be
a significant incentive. The costs connected with the use of cutting fluids are estimated to be many
times more than the labor and overhead costs. Hence the implementation of machining without
coolants (dry machining) will bring down the manufacturing costs. In dry machining, higher order
friction between tool and workpiece, and between tool and chip can lead to high temperatures in
the machining zone. This high temperature at the machining zone will ultimately cause
dimensional inaccuracies for the work-piece and tool wear problems. Therefore for pursuing dry
machining, the disadvantages associated with it have to be compensated. The minimal quantity
lubrication (MQL) can be practiced instead of dry machining. A cutting fluid for MQL should be
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selected not only on the basis of primary characteristics (cutting performance) but also of its
secondary characteristics, such as biodegradability, oxidation stability, and storage stability. Those
processes, in which the friction and adhesion play a dominant role, generally require the usage of
minimal quantities of fluid. MQL refers to the use of cutting fluids of only a minute quantity,
which are about three to four orders of magnitudes lower than that used in flooded lubricating
conditions. This will help maintain the production cost rate and overall machining product cost.
Its take minimum storage space required for cutting oil and also required minimum time for
machining.

1.7. Background
The current trend in the metal-cutting industry is to find ways to reduce cutting fluid use; the use
of coolants in machining is thought to be undesirable for economical, health, and environmental
reasons and coolant and coolant management costs are between 7.5% and 17% of the total
manufacturing cost compared to only 4% for cutting tools and stated that lubrication represents
16-20% of the product cost. The coolant cost represents about 15% of the life-cycle operational
cost of a machining process. According to a survey conducted by the European Automobile
Industry, the cost incurred on lubricants comprises nearly 20% of the total manufacturing cost
contrasted with the cost of the cutting tool which is only 7.5% of the total cost and more than 100
million gallons of metalworking fluids are used in the U.S. each year and that 1.2 million
employees are exposed to them and to their potential health hazards. The U.S. Occupational Safety
and Health Administration (OSHA) and the U.S. National Institute for Occupational Safety and
Health (NIOSH) reported that the permissible exposure level (PEL) for metal working fluid aerosol
concentration is 5 mg/m and 0.5 mg/m respectively. However, the oil mist level in the U.S.
automotive parts manufacturing facilities has been estimated to be 20 90 mg/m with the use of
conventional lubrication by flood coolant. The exposure to such amounts of metal working fluid
may contribute to adverse health effects and safety issues, including toxicity, dermatitis,
respiratory disorders and cancer. The mechanical infrastructure that sustains a flood coolant system
is of such complexity that it hinders the rapid reconfiguration of equipment. In the conventional
application of flood coolant, the chips produced are wet. They have to be dried before recycling,
which incurs additional cost. MQL on the other hand, produces essentially dry chips, so the cost
of drying them is reduced. The savings in cutting fluid and related costs could be significant if
MQL was adopted.
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