Effect of Machining Parameters on Tool Wear and Hole Quality of AISI 316L Stainless Steel in Conventional Drilling

Procedia Manufacturing 2 ( 2015 ) 202 – 207

Effect of Machining Parameters on Tool Wear and Hole Quality of AISI 316L Stainless Steel in Conventional Drilling

by: A. Z. Sultan, Safian Sharib,*, Denni Kurniawab
Politeknik Negeri Ujung Pandang, Tamalanrea, Makasar 90245, Indonesia
Faculty of Mechanical Engineering, Universiti Teknologi Malaysia, Skudai, Johor 81300, Malaysia

Abstract
This paper focuses on the effect of drilling parameters on tool wear and hole quality in terms of diameter error, roundness, cylindricity, and surface roughness. In this work, the drilling was conducted using uncoated carbide tool with diameter of 4 ± 0.01 mm with point angle of 135º and helix angle of 30º. The drilling was done at different levels of spindle speed (18 and 30 mmin-1) and feed rate (0.03, 0.045 and 0.06 mmrev-1). Austenitic stainless steel AISI 316L was the workpiece material. Comparatives analysis was done on hole diameter, roundness, cylindricity, and surface roughness of the drilled holes by experimentation. From the result, the hole quality characteristics are mostly influenced by cutting speed and feed rate. An exception was for circularity error where a two tail t-test for circularity error indicates that cutting speed and feed rate give no significant influence on circularity error. As the cutting speed increases, the surface roughness decreases (1.09 μm). Contrary, when the feed rate increases, the surface roughness value increases as well. For cylindricity error, lower cutting speed and lower feed rate will give better result. In terms of diameter error, feed rate influences more than cutting speed. Minimum diameter error was achieved when low cutting speed and low feed rate were employed.

© 2015 The Authors. Published by Elsevier B.V.
Selection and Peer-review under responsibility of the Scientific Committee of MIMEC2015.

Keywords
Surface roughness; Roundness; Cylindricity; Drilling Austenitic Stainless Steel


Concluding remarks
In drilling AISI 316L stainless steel using uncoated carbide tool with diameter of 4 ± 0.01 mm with point angle of 135º and helix angle of 30º at spindle speed of 18 and 30 mmin-1 and feed rate of 0.03, 0.045, and 0.06 mmrev-1, diameter error, cylindricity, and surface roughness are mostly influenced by the cutting speed and feed rate. The feed rate and cutting speed give no significant influence on value of the circularity error. As the cutting speed increases, the surface roughness decreases. In contrary when the feed rate increases, surface roughness value increases as well. At the same time, tool wear influences surface roughness. For cylindricity error, lower cutting speed and lower feed rate will give better result. In terms of diameter error, feed rate influenced more than cutting speed. During drilling austenitic stainless steel, drill experienced similar modes of failure at all cutting speeds and feed rates employed, i.e. non uniform flank wear, chipping, and catastrophic failure.

Acknowledgements
Financial supports from the Ministry of Education, Malaysia and Universiti Teknologi Malaysia through
Research University Grant (No. 05H27) and Fundamental Research Grant Scheme (No. 4F285) are gratefully acknowledged.

Chip Formation When Drilling AISI 316L Stainless Steel using Carbide Twist Drill

Procedia Manufacturing 2 ( 2015 ) 224 – 229

Chip Formation When Drilling AISI 316L Stainless Steel using Carbide Twist Drill

by: A. Z. Sultan, Safian Sharif,*, Denni Kurniawan
Politeknik Negeri Ujung Pandang, Tamalanrea, Makasar 90245, Indonesia
Faculty of Mechanical Engineering, Universiti Teknologi Malaysia, Skudai, Johor 81300, Malaysia

Abstract
Knowledge on the chip formation mechanism during drilling is very important to deliver the chips with size and shape as expected. Long chips cannot rid smoothly over drill flutes hence should be avoided while small chips can be removed easily from the machined hole. In this study, performance of a solid carbide twist drill through drilling of AISI 316L stainless steels was evaluated in terms of chip formation. This study aims to  better define and further characterize the different chips shape and dimensions as a function of tool wear and cutting conditions in drilling the stainless steel. Experiments conducted on various combinations of cutting speed (18 and 30 m min-1) and feed rate (0.03, 0.045 and 0.06 mm rev-1) to present the differences in chip formation. Optical observation and comparative analysis of flank wear of the twist drill were done. As the results of the performed experiments, the lowest cutting speed-lowest feed rate reveals better  performance due to desirable chips formation on austenitic stainless steels drilling.

© 2015 The Authors. Published by Elsevier B.V. Selection and Peer-review under responsibility of the Scientific Committee of MIMEC2015.

Keywords: Chip formation; Drilling; Stainless steel; Carbide Twist Drill.

Conclusions
From the results obtained in the study, the following conclusions were drawn. The drilling of  austenitic stainless steel with appropriate cutting parameters is possible without severe tool wear. The effect of cutting parameters on chip size and formation was examined. In term of desired chip formation, when using 4 mm solid carbide twist drill, a cutting speed lower than 30 m/min and feed rate 0.03 mm/rev or lower should be applied.

Acknowledgement
 Financial supports from the Ministry of Education, Malaysia and Universiti Teknologi Malaysia through Research University

Examining the Effect of Various Vegetable Oil-Based Cutting Fluids on Surface Integrity in Drilling Steel – A Review

Advanced Materials Research Vol. 845 (2014) pp 809-813
Online available since 2013/Dec/04 at www.scientific.net
© (2014) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/AMR.845.809

Examining the Effect of Various Vegetable Oil-Based Cutting Fluids on
Surface Integrity in Drilling Steel – A Review


by:
A.Z. Sultan1,2a, S. Sharif2,b and D. Kurniawan2,c
1Department of Mechanical Engineering, Politeknik Negeri Ujung Pandang, Makassar, Indonesia
2Faculty of Mechanical Engineering, Universiti Teknologi Malaysia, Skudai, Malaysia
subair@grad.its.ac.id, safian@fkm.utm.my, denni@ utm.my

Keywords: Green cutting fluids; Surface integrity; Drilling stainless steel


Abstract. Increased attention on environmental and health impacts by industrial activities forces the manufacturing industry to reduce the mineral oil-based metalworking fluids as a cutting fluid. The advantages of using vegetable oil-based cutting fluids on tool wear and the cutting force have been reported in the literature, but those reporting the effects of their use on the surface finish of the workpiece are still lacking. This mini-review gives an overview of the influence of vegetable oil based cutting fluids on surface integrity of steel during drilling process. Effect of the different cooling strategies on surface integrity is also presented.


Concluding Remarks
This mini review studies the influence of vegetable oil-based cutting fluids on surface finish of steel workpiece during drilling operation. It was found that cutting fluid, feed rate, and cutting speed have significant effect on surface roughness of the steel (AISI 304). In terms of surface roughness, MQL technique outperforms dry and conventional wet cutting. Surface roughness of austenitic stainless steel being processed by drilling using vegetable oil-based cutting fluids was very fine. At particular process parameters selected, the resulting Ra was entirely below the finish machining process threshold of 1.6 μm [24]. Literatures on effects of vegetable oil-based cutting fluids for other surface integrity, such as hole size enlargement, chip formation, cap formation, burr height, microhardness variation and residual stress are still lacking. Considering its advantages and also inconsistence due to viscosity effect on surface roughness, further research on drilling of steels is worth pursuing in search of better machining responses using alternative cutting fluids.

Acknowledgements
Financial support from the Ministry of Higher Education, Malaysia and Universiti Teknologi
Malaysia through Research University Grant (No. 05H27) are gratefully acknowledged. AZS
acknowledges scholarship from the Government of South Sulawesi Province, Indonesia.

Electrostatic Cooling System as Environmentally Conscious Cooling Technique: A Review on Its Potentials for Machining Processes

Proceedings of the
International Conference on Sustainable Energy and Development for Future Generations 2012
(ICUMI2012) 12 July 2012, Makassar, Indonesia

Electrostatic Cooling System as Environmentally Conscious Cooling Technique: A Review on Its Potentials for Machining Processes.


by: Ahmad Zubair Sultan1, Safian Sharif2, Denni Kurniawan3
1 Department of Mechanical Engineering, Politeknik Negeri Ujung Pandang, Makassar, Indonesia
2 Department of Manufacturing and Industrial Engineering, Universiti Teknologi Malaysia, Skudai,
Malaysia
*Corresponding Author. Email: safian@fkm.utm.my

Abstract
The use of excessive cutting fluids in machining has significantly improved the
productivity and quality of machined parts. However, its negative effects on the
manufacturing cost, health, and environment raise the need for alternative cooling
technique. Electrostatic cooling technique, in which ionized airflow or very fine droplets
of lubricant or coolant are generated through electrostatic charging, has positive notion
on the environment, health, and safety. This mini review paper provides overview on the
assessment of electrostatic cooling system in terms of machining responses, towards
proposing its use as an environmentally conscious cooling technique.

Keywords: Electrostatic cooling system, environmentally conscious, machining
processes

Concluding Remarks
This study reviews the performance of electrostatic cooling technique in
machining of steel and titanium alloy. In terms of tool life, cutting force, geometrical
accuracy, and surface roughness, this environmentally conscious cooling technique
outperforms dry and conventional wet cooling techniques. Literatures on its use for other
workpiece materials are still lacking. Considering its advantages, research on machining
of other worpiece materials using electrostatic cooling system is worth pursuing in
search of alternative cooling technique.

 Acknowledgements

The authors wish to thank the Ministry of Higher Education Malaysia (MOHE),
the Government of South Sulawesi, Indonesia and Research Management Center, UTM
for the financial support to this work through the FRGS funding vote number 78682