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1. Introduction
Stainless Steels are Fe-C alloys with more than 11% of Cr. Within this family,
austenitic alloys are the most resistant to corrosion. Among the austenitic steels, the
AISI 304 grade (EN1.4307) is very used for its low corrosion and high mechanical
properties (ultimate tensile strength is approximately 590 MPa). This alloy contains
18% Cr and 8% Ni, with maximum carbon composition of 0.08%. It is used in
chemical equipment, cooking equipment, cryogenic vessels, evaporators, feedwater
tubing, food processing equipment, hospital surgical equipment, hypodermic
needles, kitchen sinks, marine equipment, pressure vessels, valves, and shipping
drums.
Other important grade is the 316 (EN 1.4404), which includes Mo. Molybdenum
content increases resistance to marine environments, with better corrosion
resistance than 304. The 303 (EN 1.4305) series contains S and Mn to improve the
machinability of the alloy, being this steel included in the group known as free -
machining stainless steels. These elements (S and Mn) lead to the formation of a
protective layer of MnS on the tool rake face (Akasawa et al., 2003) (O’Sullivan &
Cotterell, 2002), where the new formed chip slips out of the edge, see Figure 1.
However, the sulphur addition lowers its corrosion resistance below that of Grade
304.
S Mn 34.39 %
Ti 21.69 %
S 16.24 %
O 10.97 %
Cr 6.35 %
Ti Ca 3.20 %
Mn Fe 2.82 %
O Si 2.72 %
Ti Si Al, Ni, N, Cu
Ca Mn
N Al Ti Cr Fe
C Mg Ti Ca Fe Ni Ni
Fig. 1: Adhered layer of MnS on the tool rake surface, and the EDAX analysis
showing Mn and S.
High performance drilling of austenitic stainless steels
Common cutting speeds in turning 304 and 316 range from 10 to 25 m/min with
HSS tools, and achieving up to 140 m/min with coated hard metal tools; while
feeds vary from 0.1 to 0.2 mm/rev. In drilling, when HSS twist drills are used
cutting speeds are from 10 to 20 m/min in 304, and from 10 to 18 m/min in 316;
feeds vary from 0.01 to 0.1 mm. When carbide tools are used speeds from 40 to 60
m/min and feeds from 0.02 to 0.15 mm/rev can be applied.
In 303 cutting speeds are higher. Thus in turning, when HSS tools are used speeds
range from 40 to 50 m/min, and feeds from 0.17 to 0.23; in the case of hard metal
tools cutting speeds exceed 250 m/min. In drilling, with HSS drill bits speeds can
be from 21 to 30 m/min and feeds up to 0.18, and when hard metal tools are used
speeds can vary from 40 to 110 m/min.
Hard metal tools with different coatings achieved low wear rates for austenitic
steels (Endrino et al., 2005). In this study, the nano-crystalline AlTiN outperformed
the fine grained AlTiN, while the texture of the AlCrN-based coatings had direct
influence on the tool performance.
Different outputs of the machining operations must be studied for machinability
consideration (Ciftci, 2006)(Tekiner & Yesilyurt, 2004):
- Tool wear, usually the flank wear measured on the clearance face of the tool,
and the notch wear on the depth of cut line in the same tool face. This aspect is
studied through long turning tests following the ISO 3685 (Tool life testing in
turning) standard.
- Roughness of the machined surfaces.
- Final dimensions of the machined parts.
This phenomenon is known as BUL (Built Up Layer) and it highly decreases tool
life (Crauwels et al., 1998). Considering the impossibility of dry machining on
some alloys, a technique of minimal consumption of cutting oils called MQL
(Minimum Quantity of Lubricant) is being used. This technique consists on the
injection of a high-speed air jet with suspensioned micro-drops of biodegradable
oil. Previous studies (Thamke et al., 1998) (López de Lacalle et al., 2001)
explained the advantages of this spray system with respect to conventional
emulsion coolant (Wakabayashi et al., 1998).
The flow of air with oil drops acts in three different ways:
- It removes the heat generated in the cutting by convection of the injected air and
by partial evaporation of the oil.
- It decreases friction between the chip and the rake face of the tool, since the oil
drops are small enough (usually smaller than 2 µm) to get into the chip-tool
interface.
- It evacuates chips from the working area helped by the pressurized air. This
aspect is very important when drilling holes with more than three times diameter
in length.
coated with a layer resistant up to 900ºC. There are no big chances of process
improvement by changing the cutting conditions.
Fig.2. Temperature along the rake face for different cutting speeds vc (80, 200, 300
and 400 m/min) and feed f 0.13 mm/rev.
300 250
250
200
Fx Fx
Fza (N)
Fza (N)
200
Fy
F(N)
150 Fy
F(N)
150
100
100
50 50
0 0
80 1 1502 3
200 4
300 5
400 1 2 3 4 5
80 150 200 300 400
Vc (m/min) Vc (m/min)
Fig.3.- Cutting forces at different cutting speeds, depth of cut a 1mm, f 0.13
mm/rev. Left) AISI 304. Right) AISI 316.
Gandarias, A., López de Lacalle, L.N., Aizpitarte X., Lamikiz, A.
3. Turning results
Two types of inserts have been used in the long life tests:
- TNMA 160408 triangular, grade KC 850, coated by three layers TiN, TiCN,
TiC (from external to internal layer). This insert has no chipbraker. Main
position angle is κ 90º.
- CNMG 120408 rhomb 80º, grade GC 4025, coated by TiN, Al2O3, and
TiCN. This insert presents chipbraker with an active clearance angle of 10º.
Position angle is κ 95º.
In Figure 5 results on 303, 304 and 316 for dry conditions are shown. Best results
were for the second insert type, due to the high clearance angle of this insert placed
High performance drilling of austenitic stainless steels
mm
0.2
0.6
rhombic
flank wear VBB
mm
0.2
AISI 316
AISI 304
0 AISI 303
Fig.5. Turning tests in 304, 316 and 303, vc 300 m/min, f 0.13 mm, a 1 mm, dry
conditions.
Gandarias, A., López de Lacalle, L.N., Aizpitarte X., Lamikiz, A.
1500
≈ ≈
machined volume VW
cm3
900
600
AISI 316
300 AISI 304
AISI 303
0
dry emulsion
8
mean roughness Ra
316 emulsion
µm
316 dry
4 304 emulsion
304 dry
2
303 emulsion
0 303 dry
0 500 cm3 1500
machined volume Vw
Fig.6. Turning tests in 304, 316 and 303, with insert CNMG, vc 300 m/min, f 0.13
mm, a 1mm, and different coolant conditions.
Some turning tests were carried out with MQL, but no improved results with
respect to dry tests were achieved. This lubrication-cooling technique did not
significantly affect the tool wear, but it produced a slightly better surface
roughness. These results are similar to those reported by Bruni (Bruni et al., 2006).
3.2 Influence of previous cryogenic treatment (CB) of the stainless steel bars
Some of the tests bars were treated by cryogenic treatment (-173º). Tool wear
development was approximately the same for treated and no treated specimens, but
better results in roughness and dimensional tolerances were found for those
cryogenically treated (see Figure 7, marked as CB), perhaps for the lower adhesion
of steel onto the tool. Aspects of secondary flank and notch wear are gathered in
Table 1.
High performance drilling of austenitic stainless steels
500
machined volume VW
cm3
300
200
8
mean roughness Ra
µm
2
AISI 304
0 AISI 304 CB
0 100 200 300 cm3 500
machined volume Vw
Fig.7. Results on 304 and 316 with and without the cryogenic treatment, turning
conditions were: insert TNMA, vc 300 m/min, f 0.13 mm, a 1 mm, dry conditions.
AISI 316 AISI 316 CB
Notch wear
Table 1. Tool wear after turning of cryogenically treated and not treated AISI 316.
Gandarias, A., López de Lacalle, L.N., Aizpitarte X., Lamikiz, A.
4. Drilling optimisation
After the turning experiments, efforts were focused on the drilling operation,
studied by previous authors (Lin & Shyu,. 2000) (Routio & Saynatjoki, 1995). The
main objective was the best selection of cutting speeds and feeds for internal
coolant with high pressure (60 bars). A secondary drive was considering the
feasibility of MQL through spindle.
4.1 Coolant techniques
Two different types of coolant technologies have been used and tested: the high
pressure trough the machine spindle and the MQL through the spindle as well. In
both cases drills with internal coolant channels were used. The channels ended on
the clearance faces.
Fig.8. High pressure coolant (60 bars) through the machine spindle and the drill bit.
High performance drilling of austenitic stainless steels
High pressure up to 60 bars was applied, using emulsion coolant (3-5% oil in
water). This technique tries to make a better use of coolant than external flooding,
achieving a large number of holes with the same drill bit and with the same oil
consumption, and therefore with the same cost of lubricants.
Looking forward to future applications, perhaps the number of holes achieved with
MQL technique might be lower but in any case, the consumption of biodegradable
oil is significantly reduced. These coolant techniques should be then evaluated
taking into account the global economic constrictions of the process for each
company and application.
There were also some experiments using dry conditions and supplying cold air (-
15º) obtained from a Vortex nozzle (by Exair™). Unfortunately there was no
improvement with respect to dry cutting. In Figure 9 the feed force and torque
along drilling for high pressure and dry conditions are shown. There is also a
picture of the drill bit after only two holes; showing chisel and primary edges
absolutely destroyed, and feed force and torque continuously increasing up till the
tool breakage.
6 thermally
N•m affected area chip adhesion
on hole´s wall
4
torque M
3
2
1
0
-1
1600
N
feed force Fz
Fig.9. Left) Feed force and drilling torque for high pressure and dry conditions.
Right) Aspect of the drill bit after two holes.
Gandarias, A., López de Lacalle, L.N., Aizpitarte X., Lamikiz, A.
30º-32º
140º
Type 1
Type 2-3
tool edges keep their features along holes production all the quality parameters are
also fine.
Types 2 and 3 presented poor results comparing to Type 1, probably due to their
weak edges at the maximum tool diameter. In this case the cryogenic treatment
seems to increase the tool performance. However there is a lack of information
about the principles of what, how and why it happens. No other observation or
evidence of the tool improvement has been found using SEM microscopy. Further
experimentation and more evidences are needed.
5.2 Influence of the cutting speed
Cutting speeds of 40 and 80 m/min have been tested. Results for both speeds were
somehow similar in relation to tool wear and hole roughness and dimension (see
Figure 11). Results were similar for 304 and 316.
Supported by the experimental data, 80 m/min cutting speed could be proposed for
mass production yielding good productivity while preserving moderate tool wear.
20 nº of drilled holes
120 250
µm
roughness Rz
10
7.00
diameter at the bottom Df
vc 40 m/min
mm
vc 80 m/min
6.90
6.85
6.80
0 2 4 m 8
cutting length c
Fig.11. Performance of the Type 2 drills in 304, at vc 40-80 m/min and f 0.13 mm,
coaxial internal coolant at 60 bars pressure.
Gandarias, A., López de Lacalle, L.N., Aizpitarte X., Lamikiz, A.
40 7.00
≈
entrance hole De
cutting length lc
m mm
20 6.90
10 6.85
0 6.80
Type 1 Type 2 Type 3
4 7.00
mean roughness Ra
µm mm
exit hole Df
2 6.90
1 6.85
0 6.80
0 10 20 m 40 0 10 20 m 40
cutting length lc cutting length lc
nº of drilled holes
new 40 400 840 980 1600
Type 1
Type 2
Type 3
Fig. 11: Performance of the three tested drills to vc 40 m/min and f 0.13 mm, in
AISI 304, with coaxial internal coolant at 60 bars pressure.
High performance drilling of austenitic stainless steels
For both materials (304 and 316), the tool coated layer avoids the adhesion of
stainless steel on the clearance and rake faces, with smoothly wear pattern. Tool
degradation came from edge chipping close to the chisel edge. In this area effective
cutting speed is low. Sticking of the drill primary edges into material instead
cutting is produced. Chip results of a plastic deformation instead of a chip removal
process. In Figure 13 the evolution of this tool wear mechanism is shown. This
wear could be reduced changing the geometry of the tool point, including a
rounded edge close to the chisel edge. Other possibility would be to increase the
cutting speed, which would eliminate the sticking, but more edge wear at the
maximum diameter would appear.
Fig.13. Type 1 drill bit, after 1045, 1650 and 1820 holes, showing edge chipping
close to the chisel edge.
a reduction in both cutting speeds and feeds. The tests with MQL were carried out
at 40 m/min and feed 0.05 mm. The maximum number of holes was hoped lower
than 500. Three types of drilling procedures were studied:
- Conventional: drilling and exiting from the workpiece at the same feed and
spindle rotation.
- Deep Hole Strategy: drilling at the same cutting speed and feed as above, but
exiting at a reduced rotational speed and at a higher feed. In this way lower
friction of the drill inside the holes is achieved and consequently low heating
is originated.
- Pecking or in&out Strategy: Cutting parameters are kept constant, but
drilling is done in steps. After each step the drill leaves the hole and
successively retrieves its position again, till the total length is drilled.
All three strategies presented bad results in comparison to the high pressure
experiments with AISI 304. The number of drilled holes never exceeded the 200.
The surface/geometric characteristics were poor. The “best” results were for
pecking, followed by conventional and deep hole strategies respectively.
Drilling with MQL is rather difficult because the ductility of materials severely
complicates the sliding of the continuous chips on the drill flutes. In Figure 14 there
are two pictures of the process corresponding to the long and continuous chip
formation.
The high-pressure system improves not only the cooling rate and transportation but
also the chip breakage. The MQL does not break chips. Figure 15 compares the
chip size/form for both lubricating systems and shows the outcome of drilling with
MQL after the tests.
High performance drilling of austenitic stainless steels
MQL chip
High-Pressure chip
The more the drilling, the higher chip accumulation on the tool. Chips can not be
properly evacuated from the work area, provoking drill to break, mainly due to the
higher torque.
Results in the case of 316 were similar to those presented for the 304, while the 303
allowed a higher number of drilled holes. Here, the turning results concerning the
influence of material groups corresponded to those in drilling, obtaining more than
300 machined holes.
6. Discussion of results and further work
Previous to the drilling study, the conducted turning tests have given relevant
information about the behaviour of these alloys when machined. Briefly, a) the rake
face temperature reaches more than 800º, b) 304 and 316 present similar
machinability indexes, and c) the cryogenic treatment seems to improve the quality
parameters: roughness and dimensional precision.
Drilling on stainless steels can rend high productivity when high pressure emulsion
coolant is injected through the spindle and drill bit. Our experiments on 304 and
316 proved operations exceeding 1600 holes.
Unfortunately, the main conclusion from experimental tests foresees a very low
number of holes produced when using MQL. Comparing the results to those
obtained under high pressure machining conditions, it is evident that high pressure
is far more effective, regardless of the high cost of lubricants and supplier
equipments.
Delving into the origin of the poor results with MQL, the main appointed reason is
the injection of the air+oil supply in a very inefficient point of the drill bit: the
clearance face of the primary edge. In this face there is not sliding of new chips on
the tool. It only happens on the rake face where there is no coolant exit. Thus MQL
has not a big effect in cutting, only some benefit coming from the general injection
Gandarias, A., López de Lacalle, L.N., Aizpitarte X., Lamikiz, A.
of air and its global cooling effect. In order to take advantage of the MQL
technique, coolant must be provided on the drill rake faces. For this purpose a new
tool with coolant channels exiting to the rake faces must be experimented. General
purpose drills present internal channels with the same channel exit, which is forced
by the primary extrusion of the hard metal bars when fabricating. The internal holes
are helicoidally placed and they would require special tool grinding to make them
successful.
New experimentation will be in the near future carried out with special designed
drills with channels to the rake faces, making them by shrinking electrodischarge
machining. This could be the key to be able to drill stainless steels with MQL
technique.
7. Acknowledgments
Thanks are addressed to the Basque companies Latz, S.Coop., Cryobest Intl.,
Balzers-Elay, and FMD SAL. Financial support from the Department of Industry of
the Basque Country Government was received, in the research project T-iNOx.
Thanks are also addressed to marGUNE research group.
8. References
Akasawa, T.; Sakurai, H.; Nakamura, M.; Tanaka, T. & Takano, K. (2003). Effects
of free-cutting additives on the machinability of austenitic stainless steels,
Journal of Materials Processing Technology, Vol. 143-144, n. 20, pp. 66-71
Bruni, C.; Forcellese, A.; Gabrielli, F. & Simoncini, M. (2006). Effect of the
lubrication-cooling technique, insert technology and machine bed material on
the workpart surface finish and tool wear in finish turning of AISI 420,
International Journal of Machine Tools and Manufacture, available on line
www.sciencedirect.com
Endrino, J.L.; Fox-Rabinovich, G.S. & C. Gey (2005). Hard AlTiN, AlCrN PVD
coatings for machining of austenitic stainless steel, Surface and Coatings
Technology, Available online www.sciencedirect.com
High performance drilling of austenitic stainless steels
Klocke, F.; Krieg, T.; Lugscheider, E. & Bobzin, K. (2001). Testing and design of
tool coatings with properties adapted to the use of biodegradable cutting
fluids, CIRP Annals - Manufacturing Technology, Vol. 50 (1), pp. 57-60
Lin,T.R. & Shyu,R.F. (2000). Improvement of Tool Life and Exit Burr using
Variable Feeds when Drilling Stainless Steel with Coated Drills, The
International Journal of Advanced Manufacturing Technology ,Vol. 16, n. 5,
pp. 308 - 313
López de Lacalle LN; Lamikiz A; Sánchez J.A, & Cabanes I. (2001), Cutting
conditions and tool Optimisation in the High Speed Milling of Aluminium
Alloys, Journal of Engineering Manufacture. Procc Int Mechanical
institution Part B, Vol. 215, pp. 1257-1268