Applied Thermal Engineering 31 (2011) 3806e3813

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Applied Thermal Engineering

journal homepage: www.elsevier.com/locate/apthermeng

Contribution to dynamic characteristics of the cutting temperature in the drilling

process considering one dimension heat flow
Lincoln Cardoso Brandao a, *, Reginaldo Teixeira Coelho b, Carlos Henrique Lauro a
a
Federal University of São João Del Rei e UFSJ, Praça Frei Orlando, 170 Centro São João Del Rei, Minas Gerais 36.307-352, Brazil
b
University of São Paulo, Department of Production Engineering, Av. Trabalhador São Carlense, 400, Sao Carlos, 13566-590 São Paulo, Brazil

a r t i c l e i n f o a b s t r a c t

Article history: The machining of hardened steels has always been a great challenge in metal cutting, particularly for
Received 22 January 2011 drilling operations. Generally, drilling is the machining process that is most difficult to cool due to the
Accepted 17 July 2011 tool’s geometry. The aim of this work is to determine the heat flux and the coefficient of convection in
Available online 31 July 2011
drilling using the inverse heat conduction method. Temperature was assessed during the drilling of
hardened AISI H13 steel using the embedded thermocouple technique. Dry machining and two cooling/
Keywords:
lubrication systems were used, and thermocouples were fixed at distances very close to the hole’s wall.
Drilling
Tests were replicated for each condition, and were carried out with new and worn drills. An analytical
Inverse Heat Conduction Method
AISI H13 Steel
heat conduction model was used to calculate the temperature at tooleworkpiece interface and to define
Temperature the heat flux and the coefficient of convection. In all tests using new and worn out drills, the lowest
temperatures and decrease of heat flux were observed using the flooded system, followed by the MQL,
considering the dry condition as reference. The decrease of temperature was directly proportional to the
amount of lubricant applied and was significant in the MQL system when compared to dry cutting.
Ó 2011 Elsevier Ltd. All rights reserved.

1. Introduction machined surfaces, simulating complex, full 3D operations. The

The importance of temperature prediction for machining
processes has been well recognized in the machining research
community due to its effects on tool wear and its constraints on
productivity [1]. The Taylor’s research in 1907 can be considered as
the starting point for the research on cutting temperatures. His
work led to the understanding and statements that by increasing
the cutting speed, the temperature also increases, causing the
decrease in tool life. Many researchers have developed analytical
models to study the thermal aspects in machining, and their
results are fundamental for calculating the temperature in many
practical processes such as grinding, milling, drilling, turning and
so on [2e5]. Heat conduction studies in machining are interesting
and necessary, because they allow define coatings for tools more
efficient in function of the degrading effect that the heat provoke
on tool performance in worked material by machining. Intense
local heat may affect the heat treatment or provoke artificial aging
and residual stress [6]. More than this, the friction coefficient and
heat partition coefficient versus sliding velocity and contact
pressure are very important in the development of new coating
[7]. The great challenge in machining is predict and control the
* Corresponding author.
E-mail address: lincoln@ufsj.edu.br (L.C. Brandao).
forecast of cutting temperatures and tool wear during machining
operations are just a few examples of new emerging needs [8].
Some authors have performed works on thermal modeling of the
machining process in the last years [9]. The experimental
approaches in the machining studies are usually expensive and
require a lot of time. The alternatives used by modern researchers
are the mathematical and computational models, in particular
computational routines developed in Finite Elements Analysis
using AbaqusÔ and ANSYSÔ. Authors as Ren and Altintas [10],
carried out experiments in interrupted orthogonal machining
using a computational algorithm. Wu and Han [11] predicted the
maximum temperature in dry drilling using finite element model
with the commercial software AbaqusÔ. The comparison between
experimental tests and simulated was carried out with using an
infrared cam. The values found for both experiments showed that
the finite element methodology has good agreement between the
measured and predicted temperature. Bono and Ni [12] analyze
the temperature profile along the cutting of a drill. The authors
used the AbaqusÔ software and demonstrated that the maximum
temperature can occur near the chisel edge. Ulutan et al. [13]
determine the three-dimensional temperatures fields on chip,
tool and workpiece. The study was critical and input to the
residuals stress prediction due to the high values of temperature.
Thus, we can considering that the researches have focused on

1359-4311/$ e see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2011.07.024
 L.C. Brandao et al. / Applied Thermal Engineering 31 (2011) 3806e3813
Table 1
Thermal and mechanical properties of tool coating (TiAl)N [25].
Coating Microhardness Oxidation
[HV, 0.1] temperature
[ C]
(TiAl)N 2750 1400
temperature and several researchers have developed finite
element techniques [14,15]. These studies show that the heat flux
and convection coefficient can be estimated by minimizing the
error between practical and theoretical values for all machining
processes such as milling, drilling and orthogonal cutting. The
studies that applied the inverse heat conduction method generally
used the embedded thermocouple technique on the workpiece to
record temperatures during the process. The method was used by
several authors estimating the thermal characteristics in milling,
average temperature on the cutting edge of tools and the heat flux
through inverted non-integer identification models. According to
Bono and Ni [15], the model can be applied to any drill or known
geometry. Using measures in drilling thrust and torque as input
parameters in an oblique cutting analysis, the model named
advection heat partition calculates the heat flux loads on a finite
element model of the workpiece. The results show that this
approach can be used to characterize tool wear or to adapt cutting
and tool material parameters to the given material and the bored
hole tolerances, and that it is capable of previewing the heat flux
in machining process. Ren and Altintas [10] set the heat flux using
finite element method applying the minimum energy principle to
total energy. Thus, they estimated the shear angle in the primary
deformation zone, based on in the model that leads to the
prediction of cutting forces and temperature produced in three
deformation zones. Kim et al. [16] implanted K-type thermocouple
to define the thermal characteristics in the high-speed ball-end
milling of hardened steel with hardness of 42 HRC. Different
cooling systems were applied in experimental tests, and
compressed chilled air at
9  C provided the best tool life among
all the cutting conditions. Brandão et al. [17] used the vortex
principle to decrease the temperature of air in milling of hardened
steel. A computational model using the ANSYSÔ software was
applied to find the heat flux and coefficient of convection in
different experimental tests environments. The vortex tube was
used near the cutting zone, and allowed decrease the temperature
in all boundary of workpiece reducing the temperature below the
environment. The solutions in the inverse heat conduction tech-
nique are obtained from the moving heat source by simply
equating the sliding velocity. In moving source problems, both
the rise in temperature as its distribution around the heat source
depend on several factors, including the heat intensity and its
distribution, the shape and the size of the heat source, the
thermal properties of material, and the sliding velocity [18].
According to Beck [19] one problem is boundary estimation and
the other is the retrospective problem. Yang [20] comments that
one of the great problems in applied inverse heat conduction is
boundary estimation where the conditions in the heat equation
are generally incompletely specified. The aim of this research is to
define the heat flux and convection coefficient during drilling of
hardened steel. The embedded thermocouple technique is used to
measure the cutting temperatures at the interface between the
tool and the workpiece. This technique was used because it is
easy to apply, but it only measures the maximum temperature in
the contact area of thermocouple with workpiece [21e23]. The
inverse heat conduction method was used to minimize the error
between the experimental temperatures and to adjust them to
theoretical curves.
3807
Surface Coating Critical Tool life
Roughness Thickness Load T, [min]
[Ra] [mm] LC, [N]
0.14 2.2 20 20
2. Experiment work
2.1. Temperature measurement
The machining tests involved the drilling process on AISI H13
workpieces with 55 HRC hardness and the average chemical
composition of: 0.40% C, 0.95% Si, 0.31% Mn, 0.011% P, 0.006% S, 5%
Cr, 0.12% Ni, 1.25% Mo and 0.13% Cu. Carbide drills were single
coated (TiAlN) with a 8.6 mm hole diameter, an overall length of
89 mm and a helix length of 47 mm according to DIN 6537 K.
Table 1 shows the thermal and mechanical properties of TiAlN.
Initially the tests were performed using new drills, recording the
temperature without the influence of wear on the standard work-
piece with a dimension of 100  40 mm and 14 mm thickness.
Afterwards, experiments were carried out on another AISI H13
plate with the same specifications, dimensions of 250  250 mm
and the same thickness until 0.2 mm of flank wear was reached,
and then tests were performed on the workpieces recording the
temperature using the worn drill. Torque in axial land thrust force
was measured in a 6272 Kistler Dynamometer for new and worn
out drills. A ROMI model Discovery 560 drilling machine center,
with 7,500 rpm and 15 kW of spindle power, was used. The
experiment conditions, chosen according to the tool manufac-
turer’s recommendation, are shown in Table 2. Table 3 shows the
thermal property of the AISI H13 steel. Fig. 1 shows the scheme of
embedded thermocouples at 0.8 mm distance from the hole
diameter, designated as Pos1.
Thermocouples were embedded in holes with a diameter of
2.3 mm and the same configuration was used for the distances of
3.3 and 5.8 mm (Dist_3.3 and Dist_5.8). Considering workpiece’s
side, thermocouples were positioned at 3.0, 7.0 and 11.0 mm from
the drill entrance, designated as T0, T1 and T2, respectively. Type
“T” Copper-Constantan Thermocouples with an AWG 30
(0.051 mm2) gauge and a temperature range from
18e205  C
were used to record the temperature. A thermostatic bath with
ethileno-glicol was used to calibrate them within the range of
10e90  C. Fig. 2 shows the general configuration of holes on
a workpiece, designed for maximizing the use of the material, and
the experiments were replicated twice for each condition. Prelim-
inary tests showed that the radial position of the holes did not
affect the heat flux in unidirectional sense and the temperature
curves due to the cutting speed generates an instantaneous quan-
tity of heat that is immediately registered by thermocouple. Thus,
the radial loss of mass in the positions DIST_5.8 and DIST_3.3 were
neglected in these regions during the final tests.
Thermocouples were connected to an electronic circuit, working
as a signal conditioner. The later was connected to a National
Instruments cardboard model PCI-MI0-16E-4 to acquire the signals.
The acquisition rate was 10 Hz for the temperature and 100 Hz for
Table 2
Experiment conditions chosen for the drilling experiments.
Tool code Hole Cutting RPM Feed
diameter speed velocity
[mm] [m/min] [mm/min]
A3269TFL*8.6 [Alpha Rc] 8.6 25 925 28
3808 L.C. Brandao et al. / Applied Thermal Engineering 31 (2011) 3806e3813

Table 3
Mechanical and Thermal properties of AISI H13 steel.

Property AISI H13 steel

Modulus of elasticity “E” [GPa] Temperature E
20 207
93 200
300 186
540 158
Poisson’s ratio “n” [e] 0.3
Density “r” [kg/m3] 7800

Specific heat capacity “cp” [J/kg. C] Cp ¼ 420 þ 0.504T
Thermal conductivity “k” [W/m. C] Temperature k
27 17.6
204 23.4
427 25.1
649 26.8
Melting temperature “Tm” [ C] 1490
Linear coefficient thermal expansion “a” [mm/m. C] Temperature

a
93 10.4
204 11.3 Fig. 1. Layout of the embedded thermocouples (Example using Pos.1 and
316 12.4 Dist_0.8 mm).
427 13.1
538 13.5
Where:
qx ¼ input heat energy due to conduction [J];
qconv ¼ Output energy due to convection [J];
the torque. The cutting fluid applied on both systems was BioG 850,
DU ¼ Internal energy [J].
a mineral-based oil, viscosity 18 cSt at 40  C, produced by Micro-
The heat source is the result of chip formation plus friction of the
químicaÔ. The MQL system Accu-Lube Precision Applicator model
tool inside the hole. The convection effect is the action of cooling
02A0-STD was assembled with two nozzle 15 mm of the cutting
system on the drilling process before and after the drill enters the
zone. The supplier recommends an input pressure between 0.55
workpiece. There is heat flux in the radial direction, but because of
and 1.05 MPa and it was regulated in the tests to 0.59 MPa. The
the high drilling speeds in the axial direction, that flux takes longer
system was set for 20 ml/h, both with integral mineral oil and
to spread and it will not be considered.
assembled at 200 mm from hole entrance. Drilling in dry condition
The energy parcels expressed as:
was employed to establish comparison. Fig. 3 shows the setup used

for the experiments and Fig. 4 shows a scheme of the MQL system. vq
qx
qx þ dx
qconv: ¼ dm $cp$vT (2)
In Fig. 4 the letter “A” inside the circle represents the line coming vx vt
from the machine’s oil tank and “B” represents the compressed air
line that comes from the accumulator located in the laboratory. Where:
dm ¼ small amount of mass;
2.2. Theoretical Temperature Evaluation cp ¼ specific heat of the material.
Using Fourier’s and Newton’s laws for cooling, Eq. (2), we can
Heat source theory was adopted to calculate the temperature of calculate:
a one-dimensional moving point. The heat source will move as

v vT vT
a moving point source in a rod that loses heat by convection. Taking
k$AC dx
h$dA$ðT
TN Þ ¼ dm$cP $ (3)
vx vx vt
a small part of that imaginary rod, as illustrated in Fig. 5, where the
dx term represent the thickness of the imaginary rod, the energy Assuming that k is the heat conductivity, Ac is the hole area, and
balance can be written down, according to Eq. (1), according to [2]: both are constants in x, since h is the convection coefficient, and
also because:

qx þ qxþdx
qconv ¼ DU (1) ðT
TN Þ ¼ q (4)

Table 4
Results of the adjustment for the heat flux and convection coefficient, in all tests.

Cooling systems Distance Thermocouple New DRILL Worn out DRILL

Heat Convection Heat Convection

Conduction [W/m2.C] Conduction [W/m2.C]
[W] [W]
FLOODING Dist-0.8 Mean value 0.63 3296.85 0.60 18511.53
Dist-3.3 0.49 3143.17 0.58 21419.60
Dist-5.8 0.26 3213.07 0.32 20080.03
Final MEAN 0.46 19857.06 0.50 20501.12
DRY Dist-0.8 Mean value 1.03 3514.44 1.19 21210.94
Dist-3.3 0.89 3547.88 0.99 22269.13
Dist-5.8 0.66 3601.29 0.64 20483.16
Final MEAN 0.86 22200.27 0.94 21357.79
MQL Dist-0.8 Mean value 0.53 2971.54 1.02 20543.80
Dist-3.3 0.55 3407.77 0.99 22012.03
Dist-5.8 0.39 3241.37 1.43 23427.25
Final MEAN 0.49 20442.13 1.15 22477.88
 L.C. Brandao et al. / Applied Thermal Engineering 31 (2011) 3806e3813 3809

Fig. 4. Scheme of the MQF system.

Fig. 2. General configuration of holes on the workpiece.

perimeter “per” and the hole area “Ac”. To solve differential Eq. (7),
Carslaw and Jaeger [2] first suggested introducing a general solu-
tion according to Eq. (10):
Eq. (3) becomes:
q ¼ m$e
n$t (10)
v2 q vq
k$AC 2
h$dA$q ¼ dm$cP $ (5)
vx vt After introducing Eq. (10) into Eq. (7) it results in:
However, if we use Eq. (6)
v2 m vm
a ¼ (11)
dA ¼ per dx and dm ¼ AC $dx$r (6) vx2 vt
The solution of which was proposed by the same authors [2]:
where:
per ¼ perimeter of the convection area [mm]; ðx
x0 Þ2
r ¼ material’s density [kg/m3]; q
m ¼ 1
exp
4$a$t (12)
We can substitute the Eq. (6) into Eq. (5), and after some 2$AC $r$cp $ðp$a$tÞ2
calculations, gives:
Where x0 is the origin of the coordinate system. Therefore:
v2 q vq
a 2
nq ¼ (7)
vt vt q ðx
x0 Þ2
q ¼ exp
n$t
4$a$t (13)
where: 2$AC $r$cp $ðp$a$tÞ
1
2

k
a ¼ (8) However the heat source is moving in relation to the coordinate
rcp
system, with speed “v”. so:
And;
x0 ¼ v$t (14)
h$per
n ¼ (9)
AC $r$cp
Where: “a” is the diffusivity of the material and “n” is a constant
which depends on density “r”, specific heat of material “cp”,

Fig. 3. Layout of the experiment. Fig. 5. Scheme of the system.

3810 L.C. Brandao et al. / Applied Thermal Engineering 31 (2011) 3806e3813

Finally: P ¼ ð2$p$n=60:000Þ$Tqtotal (19)

2
q ðx
v:tÞ
q ¼ 1
exp
n$t
4$a$t
2$AC $r$cp $ðp$a$tÞ 2
Eq. (15) gives the temperature at a certain point, x, as a function
of time, due to a moving heat source along the x axis. If a thermo-
couple is placed at x and registers the temperature-time curve,
adjusting it to Eq. (15) for the best values of q and v, one can
calculate the amount of heat absorbed by the workpiece, and also
the convection coefficient, using Eq. (9). This coefficient can be
associated with the efficiency of the cooling system in removing
heat from the workpiece. To fit Eq. (15) into the experimental
points, the following squared error function was proposed for
minimization:
Where;
(15) P ¼ Drilling Power [W];
n ¼ Drill rotation speed [rpm];
Tqtotal ¼ Total Torque [N cm];
Eq. (19) gives the drilling power generated during the drilling
process in Watts. According to Shaw [24] the value of energy that
goes in to the workpiece is equal to 10% approximately. However,
according to the author, this value has a range of 8e14% exactly due
goes to cutting conditions and process characteristics. Thus, was
considered an intermediate value of 10% due to the Shaw’s studies
was carried out in orthogonal cutting in turning process. Thus, the
theoretical value of Energy can be re-written according to Eq. (20).
P ¼ ½ð2$p$n=60:000Þ$Tqt $0:1 (20)

X
N The aim of using Eq. (20) is to compare it with the inverse heat
ε ¼ ðqi
^
qi Þ2 (16) conduction model, defining the heat flux that goes to the work-
i¼1 piece, using the temperature graphs.
Where:
qi ¼ Theoretical temperature at time I; 3. Results and discussion
^
qi ¼ Experimental temperature at time I;
N ¼ Number of measured temperature points; 3.1. Temperature measurement
The minimization procedure used a MatLABÔ program, applied,
separately, to the temperature curves at positions T0, T1 and T2. Fig. 6 shows typical temperature graphs at three positions for
Each of these curves was obtained as an average curve using those the thermocouples embedded along the drilling process for the
obtained at Dist_0.8, Dist_3.3 and Dist_5.8 and each of their repli- new drill.
cations. This procedure led to a unique curve for each drilling depth. The pattern of the temperature remained approximately the
Each fitting curve resulted in two values, q and h, which represent same for all cooling systems tested varying only at the peak values.
the energy absorbed and the convection coefficient, respectively. The drilling operation lasted about 40 s from touching the entrance
The LevenbergeMarquardt technique was used with a 1e
10 error to the returning of the drill. The time of 300 s, as shown in Fig. 6,
adjustment and a number of 10,000 iterations. This technique was necessary to permit the natural stabilization of the tempera-
consists in taking the minor errors that cause a difference between ture. The lowest temperature peak always occurred at position T0,
experimental and theoretical values and adjust the methodology, at 3.0 mm from the entrance. As the drill goes deep, more heat is
so as to correctly define the value for heat flux and of the convec- produced and accumulated at the front due to chip formation,
tion coefficient. followed by the friction of the secondary edge of the drill. The
thermocouples positioned ahead of the tool received heat wave and
2.3. Total thrust and torque prediction registered the temperature, since feed velocity was relatively low.
As the tool’s tip passes through the thermocouple position, the
The unified-generalized mechanics of cutting approach involves temperature tends to fall, because heat is lost through the work-
the development of thin shear zone analysis for drilling together piece and drilled surfaces, considering the unidirectional flux, by
with a means of obtaining the basic cutting quantities, such as the conduction, and after some time, the entire workpiece tends to the
cutting ratio (or shear angle), friction angle and shear stress, for use
in the analysis [21e23]. For this purpose, the two distinct regions of
the drill; namely, the lips and the chisel edge are analyzed sepa-
rately, before summing them up to give the total thrust force and
torque. The drilling power can be obtained by using the torque
when the feed power is ignored [21].
The total thrust force on the drill is found by summing the thrust
forces acting on the lips and chisel edge, such that:

Thtotal ¼ Thlips þ Thchisel (17)

Where;
Thlips ¼ Total thrust on the lips [N];
Thchisel ¼ Total thrust on the chisel [N];
Similarly, the total torque on the drill is given by:

Tqtotal ¼ TqLips þ Tqchisel (18)

Hence;
Tqlips ¼ Total torque on the lips [N cm];
Tqchisel ¼ Total torque on the chisel [N cm];
However, it is necessary to know the drilling power. According
to [22], the drilling power can be obtained and is given by: Fig. 6. Temperature measured with flooded system for new drills (Dist_0.8).
 L.C. Brandao et al. / Applied Thermal Engineering 31 (2011) 3806e3813 3811

same temperature also in unidirectional sense. Fig. 7 shows the

results of the temperature for all tests with three embedded
thermocouples.
The results of Fig. 7 show that the temperature behaved
according to the cooling systems and wear condition on the edge.
The temperature values raise going from the coolant system to the
dry condition, which shows the greatest values. The flooded cooling
system was the most effective system, dropping the temperature in
all radial positions of the thermocouples, therefore being the better
one for tests with worn out drills. This was because the flooded
condition maintained the temperature almost on the same range as
for the new drills. The MQL test with worn drills shows tempera-
ture values 59% greater than with new drills for the thermocouple
T1 at the radial position of 0.8 mm (Dist_0.8). This demonstrates
that the MQL system was not efficient enough to maintain the
temperature at the same level as occurred with cooling system
when the worn drill was used. The temperature difference between
worn and new drill during dry drilling was not very significant,
showing median perceptual values of 24% (Dist_0.8), and the
smallest median value was 6% for flooded system in the 5.8 mm Fig. 8. Curve fit for thermocouple T0 (flooded system).
position (Dist_5.8).
stabilizing in time of 40 s (Fig. 9) and for the third thermocouple
3.2. Fitting of the temperature curves (Fig. 10) the temperature is increasing at the same time.
As can be observed in Figs. 8,9,10 the adjustments of the
The aim of this work was to find the heat flux and convection experimental and the theoretical temperature for the first, second
coefficient using an inverse heat conduction methodology, thus and third thermocouple was almost perfect very close. It indicates
some adjustments of temperature graphs were necessary. The that the theoretical equation was capable of modeling the heat
curves were adjusted only for the time of experiments of approx- increase during the tests. There could be some inaccuracy for the
imately 40 s (30 s during the drilling and 10 s for the drill return). value of a (diffusivity), which was supposed to be 8.06e
6 in the
These adjustments were necessary because the inverse heat present work. This was observed as a general pattern for all cooling
conduction method, considering only the heat flux and the systems. Theoretical values for heat flux and convection coefficient
convection coefficient of the drilling process, takes a negligible are shown in (Table 4). The values of heat flux in Watts, and the
amount of time to stabilize naturally the temperature. The fitting results were divided by 40 s, which was the time considered during
was realized for all cooling systems and radial positions; however, the experiments and containing the peaks in temperature. This
this methodology was applied separately on each thermocouple. adjustment was necessary because the program using MatLABÔ
Figs. 8 to 10 show examples of the fitted curves for thermocouples software, considering only the heat application and convection
T0, T1 and T2, respectively, using the flooded system as example. coefficient during the drilling, does not take into account the
The distance among the thermocouples is very small, thus the natural stabilization time for the temperature. We can also observe
maximum peaks of temperature occurred almost simultaneously. that the values of Table are according to the total energy of the
However, Figs. 8 to 10 demonstrate that the behavior of tempera- drilling process. When flooded and dry cutting are compared, there
ture is different for each thermocouple. The first thermocouple is is a great tendency to heat and energy absorption to increase during

Fig. 7. Results of the temperature for all tests with new and worn drill.
3812 L.C. Brandao et al. / Applied Thermal Engineering 31 (2011) 3806e3813
Fig. 9. Curve fit for thermocouple T1 (flooded system).
dry cutting, which was 86% greater than in flooded system. This
happened because as the heat source goes deeper the temperature
increases and the heat wave goes faster than the tool, reaching the
thermocouple ahead. Dry cutting is not capable of reducing the
energy that goes in to the workpiece. Performing comparison the
flooded and MQL system shows that the variation of energy was of
only 6%. It shows that the MQL system has near the same efficiency
as the flooded system, for these experiments, without producing oil
waste in the environment. The results of the Table show that
a higher temperature gradient increases both heat absorption, and
the convection coefficient. The heat flux was proportional to the
distance of the thermocouples. These results were also similar for
worn tools with the three cooling systems. The greatest heat flux
value was found for Dist_0.8 nearest to the hole’s wall and the
lowest value was found for Dist_5.8, and this situation was similar
for all cooling systems. Comparing the average h values, no signif-
icant difference was found between both systems. This was
expected since very little heat is lost by convection inside the hole
and on both workpiece’s sides, because of the small area and the
short gradient and period. Therefore, the curve fitting can give an
indication of the magnitude of the convection coefficient that can
be expected in drilling.
Fig. 10. Curve fit for thermocouple T2 (flooded system).
Fig. 11. Torque measured with MQF system.
3.3. Torque and axial force measurement
Fig. 11 shows the Torque graphic for the MQL system where
some peaks can be observed due to the complexity of the tool
geometry. The first peak in the beginning of the drilling process,
raising the torque value, occurred because the central part of drill
did not have an edge to shear the material perfectly. The tests were
carried out without pre-drilling and thus the center of the tool
generates a crushing phenomenon. After some seconds, the two
edges start the cutting process effectively and the torque drops and
stabilizes on a specific level. Finally, at the end of the process the
Torque rises again for a longer time, according to Fig. 11, than at the
beginning of the drilling process due to the cap burr that has been
formed, according to Fig. 12. This peak occurs because the work-
piece is not drilled perfectly, thus the drill slides over the material
and it is forced to work similar to a punch tool. The thickness of cap
burr removed from the experimental tests was measured, and
corresponds to 0.09 mm, approximately in medium values.
Fig. 12 shows the results of maximum and median torque for
new and worn drills, and the theoretical values of energy spend
during the drilling process in Watts, respectively. According to
Fig. 13 we can observe that the all values for new drill has
a significant difference for worn drill. The same tendency was
maintained for the theoretical energy. Considering the use of MQL
systems, the results are according to Tasdelen et al. [26], which used
the MQL system and air-cooling, the authors support that, worn
tools showed worst performance than the new ones. According to
Rahim and Sasahara [27], the MQL outperformed dry condition on
the cutting forces, temperature, power, and specific cutting energy
because thermal cracking was severe under the dry cutting
conditions. According to Heinemann et al. [28], the MQL supply
leads to a substantial drop in tool life. Thus, the small amounts of
cutting fluid that can still reach the cutting zone seem to have
Fig. 12. Detail of cap burr formed at end of the drilling process.
 L.C. Brandao et al. / Applied Thermal Engineering 31 (2011) 3806e3813
Fig. 13. Result of the torque for the two cooling systems and the dry test for new and
worn drills.
a vital effect on tool life [28]. Considering the maximum torque
using the flooding system, as example, we can observe that the
value was almost twice for worn drill. Thus, we can support that
worn drills spend more energy of the main motor due to high
torque value independent of coolant system used.
4. Conclusions
According to the results presented in this paper, the following
conclusions can be drawn:
U The objective was to obtain a temperature gradient around the
drilling process. The difference found shows a small tempera-
ture variation between the closest position and the points
further away in the drilling process.
U In positions 2 and 3 (DIST_3.3 and DIST 5.8, respectively) the
reduction of temperature occurs because of the dissipation of heat
in the material of the workpiece rather than due to the perfor-
mance of the cutting fluid. According to this affirmation, the heat
flux was proportional to the distance of thermocouple position;
U The largest temperature reduction happened on position 1
(DIST_0.8) for the overhead flood process. This reduction was
the same regardless the tool condition;
U The computational adjustments using MatLABÔ were equal for
the three thermocouples along the axial direction, and for the three
distances (DIST_0.8, DIST_3.3 and DIST 5.8) for all cooling systems;
U The medium values of the heat flux for the cooling systems,
flooded, MQL and the dry test using new drills were 0.46, 0.49,
and 0.86 Watts, respectively.
U The decrease of temperature was directly proportional to the
amount of lubricant applied and was significant in the MQL
system when compared to dry cutting;
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