Deep hole drilling of AISI 1045: effect on hole quality & tool wear under flood, emulsion, and mist cooling technique

In recent times, the move towards sustainable manufacturing is guiding industries to adopt a low-impact manufacturing methodology that can boost productivity and reduce environmental impact. In this novel study, an evaluation of Deep Hole Drilling on AISI1045 under three different cooling techniques Flood, Emulsion, and Mist cooling was carried out. Traditionally, the flood cooling technique is used as the cooling and lubricating method, in which an increased amount of coolant is supplied with high pressure to remove chips from the machined surface. But it has negative effects on the environment, health, and machining cost. To overcome these constraints mist cooling is used as the lubricating technique which has shown promising results in many machining processes. To carry out the experimentation, three input process parameters Spindle Speed, Cutting Feed, and Pressure of the coolant were taken and Surface roughness, circularity, cylindricity, Hole wall Temperature, and tool wear were considered as output parameters to measure the hole quality. Among all the cooling techniques, mist cooling proved to be worthy in terms of attaining sustainability and produced good results in terms of Surface Finish, Tool Wear, and Hole Profile. Tool wear under mist cooling was reduced by 13–28% and 25–35% when compared with Cutting oil and emulsion, respectively, which may be attributed to reduced abrasion and adhesion under mist cooling. The surface finish was improved by 42–50% and 20–32% improved under mist cooling when compared with cutting oil and emulsion, respectively.