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Procedia CIRP 00 (2017)

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CIRP 77 (2018) 336–339
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8th CIRP Conference on High Performance Cutting (HPC 2018)

8th CIRP Conference on High Performance Cutting (HPC 2018)
Prediction and modeling of thermal distortion in sequential MQL drilling of
Prediction and modeling
28th CIRP of thermal
Design distortion
Conference, May 2018, inNantes,
sequential
France MQL drilling of
AlSi7 cylindrical parts
AlSi7 cylindrical parts
A new methodologyS.to analyze the functional and physical architecture of
Hana, P. Faverjonbb, F. Valiorgueaa, J. Rechaa*
a

existing products for an assembly

S. Han , P. Faverjon oriented
, F. Valiorgue
Université de Lyon, ENISE,
product family
, J. Recha
* identification
LTDS, UMR CNRS 5513, a 58 Rue Jean Parot, 42023 Saint-Étienne, France
Université de Lyon, ENISE,
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
b
PCI SCEMM
LTDS, - Tongtai
UMR CNRS 5513,Group,
58 RueRue Copernic,
Jean 42030Saint-Étienne,
Parot, 42023 Saint-Étienne,France
France
b
PCI SCEMM - Tongtai Group, Rue Copernic, 42030 Saint-Étienne, France
* Corresponding author. Tel.: +33-4-77-43-84-84; fax: +33-4-77-43-75-39. E-mail address: joel.rech@enise.fr
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
* Corresponding author. Tel.: +33-4-77-43-84-84; fax: +33-4-77-43-75-39. E-mail address: joel.rech@enise.fr

* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

Abstract
Abstract
A sequential MQL drilling of aluminum parts having complicated geometry is widespread in aerospace and automobile industries. However, heat
Abstract
A
fluxsequential
generatedMQL drilling
during of aluminum
sequential parts having
MQL drilling complicated
can transmit into thegeometry
workpiece is widespread
part, causinginthermal
aerospace and automobile
distortion industries.its
and compromising However, heat
dimensional
flux generated
accuracy. duringitsequential
Therefore, is necessaryMQL to drilling
predict can transmitdistortion
the thermal into the workpiece part, causing
of the workpiece thermalsequential
part during distortion MQL
and compromising its dimensional
drilling. A heat flux density
Inaccuracy.
today’s
shape business
in MQLTherefore,environment,
drilling it of a thick the
is necessary totrend
AlSi7 predict
tube towards
with more
the athermal
15-mm product
diametervariety
distortion of and
the
helical customization
workpiece
drill is unbroken.
part during
is determined after DueMQL
sequential
yielding to best
the this development,
drilling. the need
A heatmeasured
fit between flux of
density
and
agile
shape and
calculated reconfigurable
in MQLtemperatures production
drilling ofduring
a thickMQL systems
AlSi7 tube emerged
drilling. with
The aheat toflux
15-mm cope with shape
diameter
density various is products
helical andapplied
product
drill is determined
sequentially tofamilies.
after 8yielding
holes in Tothe
a design and
bestAlSi7
thin fit optimize
between production
measured
cylindrical and
part using
systems
acalculatedas temperatures
well as
finite element to choose
method during theMQL
to predict optimal
their product
drilling.
hole The matches,
center heat flux product
deviations density analysis
due toshape methods
is sequentially
thermal distortion.areSequential
needed.
applied to Indeed,
8MQL most
holesdrilling
in ofis the
a thin AlSi7
madeknown methods
cylindrical
to produce aim
part to
using
8 holes in
analyze
a finite
the aelement
product
cylindrical or one
method
part. Their product
to hole
predictfamily
center on
holethecenter
theirdeviations physical level. Different
aredeviations
measured due productdistortion.
andtocompared
thermal families,
to however,
Sequential
the calculated may
ones. MQLdiffer largely
drilling
Reasonable in terms
is made
agreement of the number
to between
produce and
8measured
holes in
nature of components.
the cylindrical
and calculated Thisdeviations
part. center
hole Their factcenter
hole impedes an efficient
deviations
are seen. comparison
are measured andand choice toofthe
compared appropriate
calculatedproduct family combinations
ones. Reasonable agreement for the production
between measured
system. A new methodology
and calculated is proposed
hole center deviations are to analyze existing products in view of their functional and physical architecture. The aim is to cluster
seen.
these
© 2018products in new assembly
The Authors. Publishedoriented product
by Elsevier Ltd.families
This is an foropen
the optimization
access articleofunderexisting
the assembly
CC BY-NC-ND lines and the creation of future reconfigurable
license
©© 2018
2018 The
assembly The Authors.
systems. Based
Authors. Published
on Datum
Published by Elsevier
Flow Chain,
by Elsevier
(http://creativecommons.org/licenses/by-nc-nd/3.0/) Ltd.
Ltd. the
Thisphysical
is an open structure
accessofarticle
the products
under the is CC
analyzed.
BY-NC-ND Functional
licensesubassemblies are identified, and
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
a(http://creativecommons.org/licenses/by-nc-nd/3.0/)
functional analysis
Peer-review is performed.
under responsibility of Moreover, a hybrid
the International functional
Scientific and physical
Committee of the architecture graph (HyFPAG)
8th CIRP Conference on High is the output Cutting
Performance which depicts
(HPC the
Selection and peer-review under responsibility of the International Scientific Committee of the 8th CIRP Conference on High Performance
similarity
Peer-review
2018). between
under
Cutting (HPC 2018). product families
responsibility of by
the providing
International design support
Scientific to
Committeeboth, production
of the 8th system
CIRP planners
Conference onand product
High designers.
Performance An
Cutting illustrative
(HPC
example
2018). of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp
Keywords: HeatPresta Franceshape;
flux density is thenSequential
carried out MQL to drilling;
give a first industrial
Thermal evaluation
distortion; of the
Cylindrical proposed
aluminum approach.
parts
©Keywords:
2017 TheHeatAuthors. Published
flux density shape;by ElsevierMQL
Sequential B.V.drilling; Thermal distortion; Cylindrical aluminum parts
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.

1. Introduction
Keywords: Assembly; Design method; Family identification this study presents (1) experimental and modeling works to
1. Introduction this study
identify heatpresents
flux into (1)theexperimental
workpiece during and modeling worksand
MQL drilling to
MQL machining has been widely in practice in an identify
(2) predict heatandflux into thethermal
measure workpiece duringinMQL
distortion drillingMQL
sequential and
MQL machining
automobile has beeninwidely
industry, especially producing in an practice
engine in an
block (2) predict
drilling of anand measure cylindrical
aluminum thermal distortion
part. in sequential MQL
1.automobile
Introduction
and a gear box industry,
because especially
MQL hasinbeen producing an engine
a promising block of
lubrication the product
drilling range andcylindrical
of an aluminum characteristics
part. manufactured and/or
and
methoda gearfor boxmachining
because MQL has been parts.
aluminum a promising heat assembled
lubrication
However, 2. Heat flux in this system. In in
identification this
MQLcontext, the main
drilling challenge
of AlSi7 tube in
Due
method for
generated to the fast
machining
during development
aluminumflows
MQL machining in
parts. the domain
into However,
the workpiece, of
heat modelling and analysis is now not only
2. Heat flux identification in MQL drilling of AlSi7 tube to cope with single
communication
generatedit during
causing and
MQL
to distort. an ongoing
machining
Attempts trend of
flows into
to identify digitization
heattheflux
workpiece,and
into the products, a limited product range or
2.1. Experimental set up and temperature measurement existing product families,
digitalization,
causing it to
workpiece manufacturing
distort.
during dry Attempts
and MQL enterprises
tomachining areheat
identify facing
and flux important
into the but
measure 2.1.also to be able to
Experimental setanalyze
up andand to compare
temperature products to define
measurement
challenges
workpiece
thermal in today’s
during dry
distortion market
and turning
in dry environments:
MQL machining
[1], dry and a
milling continuing
measure the
[2], and new product families. It can be observed
AlSi7 aluminum tube is used for the workpiece that classical existing
material for
tendency
thermal towards
dry/MQLdistortion reduction
in dry
drilling [3-8] of product
haveturning
been made. development
[1], dry
The milling times
multiple [2], and
holesandin product
MQL AlSi7 families
aluminum
drilling are regrouped
tests intube in
thisisstudy. function
used forFig.the of clients
workpiece
1 shows or features.
material for
an experimental
shortened
the flangeproduct
dry/MQL area oflifecycles.
drilling [3-8]
the have In
aluminum addition,
been made.
gear boxthere
The areis an
multipleincreasing
holes by
produced in However,
MQL
set forassembly
up drilling oriented
tests in
temperature this product
study.
measurement Fig.families
1 shows
during are
MQLanhardly to find.
experimental
drilling. An
demand
the of
flange MQL
sequential customization,
area ofdrilling. being
the aluminum at
Thermal gear the same
box are
distortion time in a
of produced global
parts having by On the product
set up workpiece
AlSi7 for temperature family level,
measurement
tube, which products differ
during MQL
has an outside mainly ofinOD
drilling.
diameter two
An=
competition
sequential
complicatedMQL with competitors
drilling.
geometry, such allthe
Thermal
as over the world.
distortion
aluminum This
ofgear
parts trend,
after main
boxhaving AlSi7
180 characteristics:
workpiece
mm, an inside tube, (i)which
the number
diameter has
of IDan=ofoutside
components
100 mm, and and
diameter of(ii)
ODthe
a height =
of
which
sequentialis inducing
complicated MQLgeometry, the such
drilling development
as the
has not been from
aluminum macro
fully studied to
boxmicro
gear yet. after type
Thus, 180 of mm,components (e.g. mechanical,
an inside diameter of ID = 100 electrical,
mm, and electronical).
a height of
markets,
sequentialresults
MQL in diminished
drilling has notlot beensizes
fullydue to augmenting
studied yet. Thus, Classical methodologies considering mainly single products
product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the
To cope with
2212-8271 © 2018this
Theaugmenting variety
Authors. Published as wellLtd.
by Elsevier asThis
to be
is anable
opentoaccess product structure
article under on a physical
the CC BY-NC-ND level (components level) which
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identify possible
© 2018 The optimization
Authors. Publishedpotentials
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
2212-8271 in This
by Elsevier Ltd. the is existing
an open access causes difficulties
article under the CC BY-NC-ND regardinglicense an efficient definition and
Peer-review under responsibility of the International
to have aScientific
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
production system, it is important preciseCommittee
knowledge of the 8th CIRP Conference
comparison of on High Performance
different productCutting (HPC 2018)..
families. Addressing this
Peer-review
2212-8271 ©under
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The Authors. of the International
Published Scientific
by Elsevier Committee of the 8th CIRP Conference on High Performance Cutting (HPC 2018)..
Ltd.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection ©
2212-8271 and peer-review
2017 under
The Authors. responsibility
Published of the
by Elsevier International Scientific Committee of the 8th CIRP Conference on High Performance Cutting
B.V.
(HPC 2018).
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
10.1016/j.procir.2018.09.029
 S. Han et al. / Procedia CIRP 77 (2018) 336–339 337
2 Author name / Procedia CIRP 00 (2018) 000–000

160 mm, is mounted on an acrylonitrile butadiene styrene The top, inside, and outside surfaces of the workpiece tube
(ABS) plate and fixed with six M8 bolts. are exposed to air. Thus, the value of free convection of air, λ =
4 W/m2K is assigned on those surfaces of the workpiece. The
workpiece tube is mounted on the ABS table and insulated, the
ø180 mm value of convection, λ = 0.1 W/m2K is assigned on the bottom
x 20 mm
surface of the workpiece.
y The heat flux density distribution moving at the feed speed
z 30 mm
50 mm of Vf = 26.9 mm/sec, which corresponds to the feed of 0.4
160 mm

Zoom A 85 mm mm/rev multiplied by the RPM of 4032 rev/min, is applied to

120 mm the drill hole’s surface. A heat flux shape in MQL machining is
divided into two zones as shown in Fig 2.
ABS Plate
ring-shaped heat flux
x
Fig. 1. experimental set up for temperature measurement during MQL y
drilling. 0.2 mm MQL drilled hole surface
The ABS plate is used to prevent heat generated during MQL x 20 mm
drilling from flowing into the milling machine table. After N3 N4 z 30 mm
50 mm
mounting the ABS plate on the milling machine table, the top N2 N5 Vf 85 mm
surface of the workpiece tube is milled and set to be z = 0 in the
0.4 mm 120 mm
z direction. A pre-drilling hole (15.2ø) with a depth of 5 mm is N1
made by milling. To embed thermocouples, small holes (0.8ø)
N6
1.0 mm
made by drilling at each depth of z = -20, -30, -50, -85, and - 1.0 mm Hot junction
120 mm in the workpiece tube. A silver glue with a thermal of
conductivity, k = 10 W/mK is injected into those small holes. Fig. 2. finite element model layout to calculate temperatures during MQL
K type thermocouples were introduced into those small holes machining.
so that the thermocouples positions were secured. All To examine contact regions between the tool and the
machining before MQL drilling were conducted with a coolant workpiece during MQL drilling, red ink is painted on the
in a 4-axis machining center, PCI METEOR GL. MQL drilling surface of the drill. After MQL machining, the ink removed
is conducted with a cutting speed of Vc = 190 m/min and a feed region on the drill is measured to be 27 mm and modelled as the
of f = 0.4 mm/rev. Oil mist is generated at a pressure of p = 5.5 friction zone with linearly decreasing heat flux density from the
bar and supplied through the spindle. Depth of drilling is 120 maximum heat flux density, 𝑞𝑞̇ max as shown in Fig. 4. Hot chips
mm. Temperatures during MQL machining was recorded in the and oil mist during MQL drilling evacuate through the drilled
data acquisition system. Three replications of temperature hole. Considering their possible convective heat transfer
measurements were made. After MQL machining, an optical effects, the linearly decreased shape from 10% of the maximum
micrograph to show the cross section (denoted as zoom A) heat flux to zero is used in zone 2.
reveals that a hot junction in the thermocouple is located at 1.0
Maximum heat flux
mm on the average from the MQL drilled hole’s surface.
(a) density, 𝑞𝑞̇ max (W/mm )
2

2.2. Temperature calculation during MQL drilling 10% of Maximum heat Vf (mm/sec)
flux density
A numerical temperature calculation model layout for MQL
drilling is shown in Fig. 2. A finite element method software, Zone 1 :
SYSWELD® is adopted. A tri-quad 2D meshes is extruded with Zone 2 : Friction zone
a depth of 160 mm in the z direction so that 3D meshes of the 27mm
93 mm
tube are generated using VisualMesh®. A drilled hole with a (b)
depth of 130 mm is present in the 3D meshes of the workpiece.
As shown in Fig. 2, in the region denoted as zoom B, 3D mesh
has 0.4 mm in the x direction and 1 mm in the z direction. The
temperature dependent workpiece material properties of AlSi7
are assigned on the workpiece elements as given in Table 1. Fig. 3. (a) heat flux density distribution; (b) red ink removed region on the
drill after MQL drilling.
Table 1. Temperature dependent workpiece material properties of AlSi7 [8]. Workpiece temperature rise during the MQL drilling is
calculated using SYSWELD®. The hot junction (0.3ø) of the
Material property At 20 °C At 100 °C At 150 °C embedded thermocouple (See Fig.1) is located at d = 1.0 mm
Density (kg/m3) 2670 2670 2670 from the MQL drilled hole’s surface. Temperatures at six nodes
Thermal conductivity (W/m K) 125 152 158 from N1 to N6 around the hot junction (See Fig. 2) of 5
Specific heat (J/kg K) 820 820 820 thermocouples, embedded at the depth of z = -20, -30, -50, -85,
and -120 mm, were extracted and averaged.
Expansion coefficient (μm/m K) 22.6 22.6 22.6
338 S. Han et al. / Procedia CIRP 77 (2018) 336–339
Author name / Procedia CIRP 00 (2018) 000–000
2.3. Heat Flux Identification
Measured temperatures using 5 embedded thermocouples in
the section 2.1 and calculated temperatures in section 2.2 are
plotted together with respect to time in Fig. 3.
Fig. 4. calculated and measured temperatures vs. time during MQL drilling.
With an iterative identification algorithm, the maximum
heat flux density, 𝑞𝑞̇ max = 0.77 W/mm2 with linearly decreasing
to 75% of that within the friction zone 1 (See Fig. 3 (b)) yields
the best fit between measured and calculated temperature
profiles.
3. Thermal distortion in aluminum cylindrical parts in
sequential MQL drilling
3.1. Experimental set up
Automobile gearboxes have a flange with a series of holes
and sequential MQL drilling is widely being performed in the
automobile industry. Thus, as shown in Fig. 5, cylindrical
workpiece with 8 holes is adopted to predict and validate
thermal distortion in parts having a flange shape.
Fig. 5. experimental set up in sequential MQL drilling of AlSi7 cylindrical
part.
The cylindrical workpiece part has an inside diameter of 120
mm and an outside diameter of 160 mm, and a height of 30 mm.
3
It is mounted on ABS plate. The centering hole is fixed with an
M8 bolt, resulting in no displacement (UX=UY=UZ=0). A pin
in the locating hole is put into the slot on the ABS plate,
allowing it to move in the x direction (UY=YZ=0). Sequential
MQL drilling with a drill (15ø through-hole) from hole #1 to
hole #8 were performed. Drilling were performed with a cutting
speed of 190 m/min, feed of 0.4 mm/rev, and MQL pressure of
5.5 bar. After sequential MQL drilling of the cylindrical parts,
hole center deviations of each drilled hole are measured using
a coordinate measurement machine (CMM) are given in Fig. 6.
The centering hole of the cylindrical part is the origin in the
CMM coordinate. Its top surface is set to be Z = 0 mm. The
magnitude, U of each hole center deviation, (dX, dY)
represents the amount of dimensional error of each hole after
sequential MQL drilling.
80 Measured hole
center
Theoretical hole
center
40
Y axis in milling machine
0
-80 -40 0 40 80
-40
-80in milling machine
X axis
Fig. 6. hole center deviation, (100×dX, 100×dY) at the middle section (z
= - 15 mm) of the part in the milling machine coordinate.
3.2. Modeling work to predict thermal distortion in sequential
MQL drilling
This section outlines a calculation work to predict thermal
distortion of the cylindrical part in the sequential MQL drilling
as described in the section 3.1. The CAD model and 3D
generated mesh of the cylindrical workpiece are shown in Fig.
7. As shown in Fig. 6, a tri-quad 2D meshes is extruded with a
depth of l = 30 mm so that 3D meshes of the cylindrical part
are created using VisualMesh®.
Fig. 7. calculated displacement, normalized U (when drilling hole #8) in the
CAD model and 3D generated mesh of the cylindrical part (unit: mm).
 S. Han et al. / Procedia CIRP 77 (2018) 336–339 339
4 Author name / Procedia CIRP 00 (2018) 000–000

Temperature dependent workpiece properties of AlSi7 as machining agrees well with the experimentally measured hole
given in Table 1 are assigned on the 3D elements. The value of center deviation.
free convection of air, λ = 4 W/m2K is assigned to the top,
0.045
internal, and external surfaces of the cylindrical part. The value Hole center
0.04 deviation
of convection, λ = 0.1 W/m2K is set to the bottom surface
0.035

Displacement (mm)
because it is mounted on the ABS plate and insulated. 0.03
Displacement at the centering hole is set to be zero in all Calculated
0.025 thermal
directions, UX = UY = UZ = 0. Displacement at the locating 0.02 distortion
hole is set to be zero in the Y and Z directions, UY = UZ = 0. 0.015
The identified heat flux of 𝑞𝑞̇ = 0.77 W/mm2 moving at a feed 0.01
speed of Vf = 26.9 mm/sec (See Fig. 3) is applied to each hole 0.005
from hole #1 to #8 in sequence. Since each drilling is made in 0
every 2.5 seconds, the moving heat source is sequentially 1 2 3 4 5 6 7 8
applied to each hole in every 2.5 seconds. Temperature and Hole number
displacement of the cylindrical part in sequential MQL drilling
Fig. 9. Comparison between experimental and calculated thermal distortion;
are calculated. Normalized U at 4 nodes at the middle sections
measured hole center deviation and captured displacement at the middle
of each hole in the cylindrical part are averaged and plotted section of each drilled hole.
with respect to time in Fig. 8.
4. Conclusions
0.045
0.04 Hole #1
Heat flux is generated and applied to the workpiece by MQL
0.035 Hole #2 drilling. Its heat flux density shape, which yields the best fit
Displacement (mm)

0.03 Hole #3 between measured and calculated temperature profiles, was

0.025
0.02
0.015
0.01
0.005
0
Drilling hole #1, #2, #3, #4, #5, #6, #7, #8
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
Time (sec)
Fig. 8. calculation results: displacement of hole center vs. time at the middle
section of each hole.
Fig. 8 shows that each hole center moves due to repetitive
expansions and contractions during sequential MQL drilling.
At 11 seconds just before drilling hole #5, its displacement
reached 15 μm due to thermal expansion caused by heat flux
applied to previous holes from #1 to #4. It can be noted that the
cylindrical part is being thermally distorted during MQL
drilling series of holes. Thus, drilling of each hole can be made
on the thermally distorted part, that is to say, on the deviated
position from the target (theoretical position). The moment at
which drilling of each hole is made and corresponding
displacement are indicated as red arrows in Fig. 8. These values
of 8 holes are considered to be the calculated hole
displacements due to thermal distortion and plotted together
with measured ones in Fig. 9.
Large hole center deviation of about 40 μm is seen at hole
#4 and #5 in Fig. 9. In addition to hole center deviation due to
thermal distortion, a machine precision error can occur. It may
come from linear motion of a spindle and a tool in the z
direction when drilling. Hole center deviation, when drilling
only one hole of fully clamped cylindrical part with coolant, is
measured to be 10 μm. It can be said that the prediction of
thermal distortion of the cylindrical part due to sequential MQL
Hole #4
determined. Its heat flux shape is sequentially applied to 8 holes
in a thin cylindrical part. Their hole center deviation due to
Hole #5
thermal distortion of the part during MQL drilling is predicted
Hole #6 and compared to the measured one. Reasonable agreement
Hole #7 between the measured hole center deviation and predicted
thermal distortion is observed.
Hole #8
Acknowledgements
The authors are grateful to IMPULSA project to support this
research.
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