CHAPTER 1

INTRODUCTION

Dry machining processes are much better for environment than classical machining
processes using coolant. On removing coolant, we need to develop the new technologies
needed. The productivity of these technologies is now very good and is equivalent to the
classical productivity rates. The main question is to know if these new emerging technologies
are fundamentally better for the environment. The new technology developed is said to be dry
technology, here splitting of the chip in deep drilling can be obtained by vibrating the drill
axially. The studies conducted on self-vibratory drilling (SVD) has led to the design of a
drilling head compatible with the existing tools and machines, and that does not require
additional energy. The aim of this paper is to demonstrate that the environmental impacts
generated by SVD over an industrial production are significantly less than those of TD and to
quantify them.

For that purpose here we are comparing both traditional and SVD with the help of
graphs. The graph comparing the relative weight of environmental impacts of the two
processes according to the 10 indicators like abiotic depletion, acidification, eutrophication,
global warming, ozone layer, human toxicity, fresh water aquatic ecotox, marine aquatic
ecotoxicity, terrestrial ecotoxicity, photochemical oxidation. The negative impact created by
dry machining is that it produces high temperature during the friction between the tool and
the work piece, somehow this can be counteract by providing a interrupted machining
environment. Dry machining also helps in the reduction of thermal shocks.

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1.1. LITERATURE SURVEY

Sreejith PS, Ngoi BKA were the first to conduct study on Dry Machining: They
introduced this kind of machining as it reduced the use of coolant to its maximum, thereby it
seems to be the machining of the Future. Then it was Tichkiewitch S, Moraru G, Brun-Picard
D, Gouskov A who conducted experiments later and provided with the idea of Self-Excited
Vibration in Drilling Models in order to remove chips during machining. Hauschild M,
Jeswiet J, Alting L studied on From Life Cycle Assessment to Sustainable
Production.Canter NM ,Onder O, Paris H, Rech J, Grenier L also studied on Self-Vibratory
Drilling: An Answer for Sustainable Manufacturing.

1.2. OBJECTIVES

To demonstrate that the environmental impacts generated by SVD over an industrial

production are significantly less than those of TD
To know, after the coolant is removed, what the main contributors to the environment
are to optimize the machining process.
To discuss different approaches of manufacturing processes using Life Cycle Analysis
(LCA).

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 CHAPTER 2
NEED FOR A COOLANT IN MACHINING

A coolant is a fluid which flows through a device to prevent its overheating,

transferring the heat produced by the device to other devices that use or dissipate it. An ideal
coolant has high thermal capacity, low viscosity, is low-cost, non-toxic, and chemically inert,
neither causing nor promoting corrosion of the cooling system. Some applications also
require the coolant to be an electrical insulator. While the term coolant is commonly used in
automotive, residential and commercial temperature-control applications, in industrial
processing, heat transfer fluid is one technical term more often used, in high temperature as
well as low temperature manufacturing applications. A coolant can be any phases like gases,
liquids, molten metals and salts and solids.

Fig 2.1 Coolant delivery nozzle

The purpose of the application of the cutting fluids in metal cutting was stated as
reducing cutting temperature by cooling and friction between the tool, chip and work piece
by lubrication. Chip formation and curl, which affects the size of the crater wear and the
strength of the cutting tool edge, is also affected when coolant is carried out during
machining. Generally, a reduction in temperature results in a decrease in wear rate and an

3
increase in tool life. However, a reduction in the temperature of the work piece can increase
its shear stress, so that the cutting force may be increased and this can lead Water soluble
fluids were defined suitable for operations where cutting speeds were very high and pressures
on the tool were relatively low. Neat cutting oils are straight mineral oils, or mineral oils with
additives. Coolant is very much useful in machining for removal of heat generated due to
friction. Under high pressure, coolant is essential to split and evacuate the chip in deep
drilling. It also provides the tool with better life and surface finish. This is achieved by the
coolant by safely removing the chips produced during drilling and removing excess heat
developed during machining process. During drilling there may be also having the possibility
of edge formation, these are also removed by the use of coolant.

Every conceivable method of applying cutting fluid can be used, with the best choice
depending on the application and the equipment available .For many machining applications
the ideal has long been high pressure, high volume pumping to a force stream of liquid
directly in to the tool chip interface, with walls around the machine to contain this splatter
and the sump to catch, filter, and recirculate the fluid. This type of system is commonly
employed, especially in manufacturing. It is often not a practical option for MRO or hobbyist
metal cutting, where smaller, simpler machine tools are used. Fortunately it is also not
necessary in those applications where heavy cuts aggressive speeds and feeds and constant all
day cutting are not vital.

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 CHAPTER 3
DRY MACHINING TECHNOLOGY

It is an ecologically desirable process by which the environmental impacts created by

usage of coolants can be reduced. The splitting of the chip in deep drilling can be obtained by
vibrating the drill axially. The studies conducted on self-vibratory drilling (SVD) has led to
the design of a drilling head compatible with the existing tools and machines, and that does
not require additional energy. This technology is candidate to automotive industry and should
be environmentally qualified and optimized in practical working conditions. During SVD, the
axial vibrations that cause the splitting of the chip are obtained by the instability of the cut.
The cutting parameters selected in SVD maintains or improves productivity by referring to a
drilling operation using a twist drill. A special drill holder called self-vibrating drilling head
(SVDH) was developed .The SVD is composed of three main elements; the drill holder called
sliding body, with a mass m, fixes the twist drill and enables axial vibrations. The vibrating
device body connects the device to the spindle and the leaf spring, with a stiffness k, is a
dynamic cutting fixture enabling a magnitude and an adapted frequency. The cutting
parameters are chosen to be in the area of unstable cutting. The chip is then naturally
evacuated without coolant.16-20% of manufacturing costs lowered. Hence it is much cheaper
to involve this technology. The main pecularity of using dry machining is that it causes less
pollution when compared with traditional drilling. Waste materials that are disposal is very
much less and it does not cause pollution to atmosphere and water. The health problems
caused by this technology is less when compared with traditional drilling.
Many metal cutting processes have been developed and improved based on the
availability of coolants. It is well known that coolants improve tool life and tool performance
to a great extent .In dry machining there will be more friction and adhesion between the tool
and the workpiece, since they will be subjected to high temperatures. This will result in
increased tool wear and hence reduction in tool life. Dry machining has some positive effects
such as reduction in thermal shock and hence improved tool life in an interrupted-machining
environment. Research in dry machining has led to the following achievements such as an
under cooling system, an internal cooling by a vapourisation system, cryogenic systems,
thermo cooling systems. Another approach is to improve the properties of tool material by
making them more refractory or generate less heat during machining. There has been a
continuous development in the field of cutting tool materials starting with HSS, cobalt alloys,
cemented tungsten carbide, coated carbides and coated HSS, cubic boron nitride and

5
diamond. The need for machining with increasingly higher cutting speeds and also to
machine difficult to machine materials are imposing pressure for the development of new tool
materials. As a result newer tool materials such as ceramics and also different types of
coatings on the tool materials will address the problems in dry machining to some extent.

Fig.3.1 Self vibrating drilling head.[2]

Here the chips are naturally fragmented to small pieces implying that there is no need
to perform the stripping operations classically used to split up chips. The friction of chip on
the manufactured hole surface is limited which leads to improved hole quality. The drill is
made of cemented tungsten carbide drill of 5 mm diameter with a split point grinding. The
hole produced by this drill is about a length of 90 mm. Cemented tungsten carbide is used
because of its ease to machine hard materials such as carbon steel or stainless steel, whereas
at these tough conditions other tools would easily wear away such as high quantity
production runs. These carbide tools also provides better surface finish and allow faster
machining. Carbide tools can also withstand higher temperature than standard high speed
steel tools which are used as drill material. Three main elements; the drill holder called
sliding body, with a mass M, fixes the twist drill and enables axial vibrations; vibrating
device body, a leaf spring of stiffness k. Axial vibrations remove metal chip.[3]

Another approach consists in using the cutting energy to create the axial vibrations
necessary to split the chips. The objective is then to set up the cutting conditions in order to

6
create drill axial chatters. The axial vibrations at low frequency have amplitude bigger than
the feed rate allowing the chip to be split and easily removed by the cutting uid.

Fig.3.2 Basic elements of SVDH.[3]

3.1 DYNAMIC MODEL OF SVDH

The machining of deep holes is limited due to inadequate chip evacuation, which
induces tool breakage. An alternate response is the use of dry vibratory drilling. A specific
tool holder induces axial self-maintained vibration of the drill which enables the chip to be
split. The chips are thus of smaller size and can be evacuated.Elements constituting the
machining system (machine tool, work piece, fixture and cutting tool) have a stiffness higher
than the axial stiffness of the SVDH. The spring of the SVDH has a very big rigidity in
twisting and low rigidity in compression. The dynamic behaviour of the machining system
was modified as a second order system characterized by a mass (m), stiffness (k) and
damping (c).For a hole diameter of 5 mm, a mass m of 3.2 kg, a stiffness k of 380 N/mm, the
range of the rotation speed is between 7000 and 14,000 rpm. The surface generated by a lip
of the drill is the result of the axial feed of the drill and of the spindle speed. The cutting force
in drilling are modified by a thrust force and a torque around the drill, with the hypothesis
that the sharpening of the tool and that the lips of the drill work in the same way, the lateral
force being on every lip counterbalance.

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 Fig.3.3 Dynamic model of SVDH.[1]

The cutting forces in drilling are modelled by a thrust force and a torque around the
drill, with the hypothesis that the sharpening of the tool is perfect and that the lips of the drill
work in the same way, the lateral force being on every lip counterbalance. Juhchin proposed a
cutting thrust force model where this force was proportional at the uncut chip section.This
model does not take into account the non linear behaviour generated by the indentation force
on the chisel edge. Indeed, this zone of the drill has a geometry that does not facilitate the
cutting. Furthermore in this small region around the center of the chisel edge, the tool did not
cut but instead extruded the material.

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 CHAPTER 4
EXPERIMENT
The goal of this study is to prove that the environmental impacts of SVD are
significantly less than those of TD and to quantify them. The study was based on an (LCA)
life cycle analysis of the two processes and illustrated on the machining of industrial
crankshaft lubrication holes. The holes diameter is 5 mm and the depth is 100 mm. The
crankshaft is made of steel 35MnV7. The other manufacturing steps of the crankshaft are not
taken into account. The assessment and comparison of the environmental impacts of the two
processes are based on the machining of crankshaft lubrication holes over 5 years of
production. The manufacturing system is working 22 h per day, 47 weeks per years, and
produces 6026 crankshaft per week. The machining time of the holes is the same regardless
of the process so the two processes will produce the same number of crankshafts, with holes
of the same quality.

The study is conducted over three main life cycle phases:-production, use and end-of-
life (EOL) phases. The system includes all elements necessary to drill the crankshafts: the
milling machine, the lubricant system and all the machines to process it before, when and
after the drilling operation, the drill and the drill head, the chip system and all the machines to
treat them until recycling. The production phase deals with the processes to obtain every
element of the system. It includes the obtaining of the raw materials, the energy consumed to
process them and the transportation needed to produce the 5 axes milling machine, the
drilling heads, the twist drills and the coolant. The transportation of each element from the
manufacturer to the crankshaft production site is also included.

The use phase includes the energy consumption of the milling machine when
processing and the energy consumed by the additional machines that are necessary for the
treatment of the soiled chips: chip crusher, spinner, centrifuge and washing machine. The
EOL phase addresses the transport of waste (chips, twist drills, drill heads and coolant) from
the production site to their recycling sites. LCA is made using SimaPro software. Each
element included in the boundaries of the study has been decomposed in subsystems, and
each subsystem in components. For each component, the weight (or volume) of material has
been associated from the database of the software, as well as the manufacturing processes
that are required.

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 CHAPTER 5
RESULTS

The comparison carried out between TD and SVD, using SimaPro, of the relative
weight of the environmental impacts of these two processes, according to 10 indicators:-
Abiotic depletion, Acidification, Eutrophication, global warming, Ozone layer, Human
toxicity, Fresh water aquatic ecotox, Marine aquatic eco-toxicity, Terrestrial eco-toxicity,
photochemical oxidation. The results shows that the environmental impacts created by SVD
is much lesser than that of TD.TD uses more energy for the treatment of soiled chips,
whereas SVD the energy consumption in the use phase is the major consumer of energy.
Comparing these two graphs we can find that the major contributors of environmental
impacts are the coolants used during traditional drilling. They contribute to about 85% of the
environmental impacts.

Abiotic depletion refers to the degradation of the non-living chemical and physical
factors in the environment. Abiotic factors can be classified as light, water, atmospheric gases
and soil. Acidification is caused due to excess protons present which will affect the pH of
either the soil or oceanic environment. Eutrophication is the ecosystems response to the
addition of artificial or natural substances such as nitrates and phosphates. The waste
produced from a machining process could also include that kind of waste, these waste when
in contact with lakes or rivers leads to eutrophication. Global warming is the rise in the
average temperature of earths atmosphere and oceans mainly due to the presence of
increased concentration of greenhouse gases. Ozone layer depletion is also caused due to
presence of CFCs and other contributory substances referred to as ozone depleting substances
mainly UV light. Human toxicity refers to the contents which causes harmful effects to
humans, the harmful waste materials and dusts produced during machining processes also
contains wastes that are harmful to humans. Fresh water ecotox refers to the harmful effects
created to the fresh water aquatic environment due to the dumping of waste produced during
machining affecting that ecosystem. Terrestrial ecotox means the harmful effects created in
the terrestrial eco system due to the waste formed during machining. Photo chemical
oxidation is the oxidisation process to produce harmful elements that are harmful to
environment when the ultra violet rays react to that substrate.

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5.1 Environmental impacts of td during its life cycle
The figure shows the relative weight of the contributors to the environmental impacts,
on a scale of 100%. It can be seen that the main contributors are the energy required for the
treatment of soiled chips (red part) and the use of consumables (grey part). The other minor
contributors are the energy consumption during the use phase (yellow part) and the
production of the milling machine (blue part). Furthermore, among the consumables parts, it
was noted that it is the production and EO-L of the coolant that generate at least 85% of the
environmental impacts (the production and E-O-L of the twist drills and drill heads
generating the remaining impacts)

Fig.5.1 Environmental impacts of td during its life cycle.[2]

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5.2 Environmental impacts of SVD during its life cycle

Fig.5.2 Environmental impacts of SVD during its life cycle.[2]

This figure shows the relative contribution of the production of milling machine (blue
part), the E-O-L of milling machine (red part), the energy consumption during the use phase
(yellow part) and the use of consumables (green part) to the environmental impacts of SVD,
on a scale of 100%.All the impacts have the same profile and consumables are responsible for
at least 70% of the environmental impacts, with the exception of one indicator: terrestrial
eco-toxicity. This exception is mainly due to the energy consumption of the manufacturing
process.

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5.3 Environmental impacts of TD and SVD during its life cycle

(TD- GREEN , SVD- RED)

The given figure shows that SVD generates at least 90% less environmental impacts
than TD. The use of coolant in TD generates at least 90% of the environmental impacts
during the drilling operation of crankshafts. The major contributors in SVD are the
consumables (around 70% of the impacts) and mainly the twist drills

Fig.5.3 Environmental impacts of TD and SVD during its life cycle.[2]

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 CHAPTER 6
CONCLUSIONS

The use of coolant in TD generates at least 90% of the environmental impacts during
the drilling operation. The environmental impacts of Self Vibratory Drilling are significantly
less than those of Traditional Drilling. The studies conducted on self-vibratory drilling (SVD)
has led to the design of a drilling head compatible with the existing tools and machines, and
that does not require additional energy. It is feasible in a very near future to increase the
lifespan of twist drills, by optimizing the geometry and the material of the tools. Research in
dry machining has led to the following achievements such as an under cooling system, an
internal cooling by a vapourisation system, cryogenic systems, thermo cooling systems.
Another approach is to improve the properties of tool material by making them more
refractory or generate less heat during machining. There has been a continuous development
in the field of cutting tool materials starting with HSS, cobalt alloys, cemented tungsten
carbide, coated carbides and coated HSS, cubic boron nitride and diamond. The need for
machining with increasingly higher cutting speeds and also to machine difficult to machine
materials are imposing pressure for the development of new tool materials. As a result newer
tool materials such as ceramics and also different types of coatings on the tool materials will
address the problems in dry machining to some extent.

14
 REFERENCES

[1] Paris H., Brissaud D., Gouskov A., Guibert N., Rech J., Influence of
the Ploughing Effect on the Dynamic Behaviour of the Self-Vibratory
Drilling Head. CIRP Annals 57[2008], page 385388.
[2] Paris H., Matthieu Museau., Contribution to the environmental
performance of the dry-vibratory drilling technology. CIRP Annals-
manufacturing technology 61[2012], page 47-50.
[3] Paris H., Tichkiewitch S., Peigne G., Modelling the vibratory drilling
process to foresee cutting parameters. CIRP Annals 54[2005],page 367
370.

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 QUESTIONS & ANSWERS

1. What is the major advantage of using dry machining over traditional drilling?
The main advantage of using this technology is that it is environmental friendly,
it causes less pollution and less allergic diseases for human beings. It produces less
manufacturing cost too.

2. How manufacturing costs are reduced while using dry machining?

By providing with dry machining the additional energy given for injecting the
coolant is reduced as a vibrating body is provided which in turn takes the energy
provided during machining.
3. What is the material used in the drill bits? What is the advantage in providing those
kinds of materials?
They are mainly carbide tools which are used in machining here, they are
provided as they are having very high toughness and they can withstand up to a very
high temperature.

4. What is the major draw back in using this technology?

Dry machining prevails in an interrupted environment, which takes up so much time

during machining. Also the drill bits also suffers from major deterioration as it is
working at a very high temperature.

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