Application of minimum quantity lubrication when drilling nickel-based superalloy at high cutting speed

Nowadays, an increase on demands of aerospace components has led to implementation of high speed machining (HSM). The principal factors in the performance of aerospace materials are strength-to-weight ratio, fatigue life, fracture toughness, survivability and of course, reliability. However, when HSM is coupled with dry or near dry machining, it will present considerable technical challenges to the manufacturing sector especially when the integrity of the machined surface is concerned. In this investigation, the effect of high speed drilling (HSD) conditions on the performance and surface integrity of Inconel 718 were studied. Hole was drilled individually using TiAlN coated carbide insert drill (14 mm in diameter) under minimum quantity of lubrication (MQL) condition. Results showed that uniform flank wear and chipping were the dominant tool failure modes. Moreover, the results showed an increase in cutting temperature with increasing cutting speed and feed rate. Thrust force and torque decreased linearly with the increasing cutting speed but significantly increased when higher feed rate is employed. Cutting speed significantly influenced the distribution of surface roughness value. Variations of hardness readings were recorded beneath the machined surfaces, they were due to the hardening effects caused by concentration of high temperature and stresses on the workpiece. © 2009 Trans Tech Publications, Switzerland.