Study of dry and minimum quantity lubrication drilling of novel austempered ductile iron (ADI) for automotive applications

Coolants and lubricants for machining can improve the machinability of the workpiece, increase productivity, and extend tool life by reducing tool wear. However, for environmental and economic reasons, recent research in industry and academia has sought ways to reduce the use of machining fluids. This paper reports the use of dry and minimum quantity lubrication (MQL) to drill austempered ductile iron (ADI), a new class of materials used for light weight automotive components like connecting rods and crankshafts. In this study, ADI is produced by a novel processing technique known as continuous casting-heat treatment process. The novel technique is developed by the integration of casting (in die casting) and heat treatment processes in the foundry to save energy and time. This paper deals with an experimental investigation on the role of MQL drilling on the cutting forces, tool wear and surface roughness of newly produced ADI at industrial speed-feed combinations by TiAlN-coated tungsten carbide tool. MQL drilling, performance is then compared with the dry and conventional drilling process under the same experimental conditions and environment. The results include significant reduction in tool wear, cutting forces and surface roughness by MQL drilling, mainly through reduction in the cutting zone temperature.