DRY MACHINING

Under the guidance of

Prof. S. R. Patil

Presented
byCHETAN S. CHAUDHARI
T.E. MECHANICAL SANDWICH

Points to be Covered

Machining
Conventional Machining
Purpose of Fluids
Disadvantages of Fluids
Dry Machining
Methods
Advantages
Disadvantages
Applications
Conclusion

Machining

Process of removing the material from the work piece

to obtained the piece of desired shape
e.g. Drilling,
Boring,
Cutting,
Grinding

Conventional Machining

Wet Machining - Most preferred or used in most of

the operations.

As name suggests machining fluid is used for

processing.

Purpose of Fluids

To lubricate and reduce friction between tool and

work piece.

To dissipate the heat generated due to plastic

deformation of the metal.

To cool the work for preventing thermal distortion of

the work.

To cool the tool for increasing the tool life

Disadvantages of Fluids
Economic Reasons Cost of tooling.
Manufacturing cost
Cost of Fluids
Environmental Reasons

Difficult in disposal.

Fluids contaminate the air.

Causes employee health problems.

Methods of Achieving Dry Machining

TOOL
TOOL
MATERIAL
MATERIAL

THROUH
THROUH
SPINDLE
SPINDLE
AIR
AIR

TOOL
TOOL
COATINGS
COATINGS

DRY
DRY
MACHINING
MACHINING

HIGH
HIGH
SPEED
SPEED
MACHINING
MACHINING

NEAR
NEAR DRY
DRY
MACHINING
MACHINING

Tool Materials

Tungsten Carbide

High Speed Steel.

Cemented Carbide

Maxamet Alloy

Tool Coatings

Materials Titanium Nitride (TiN)

Titanium Aluminium Nitride (TiAlN)
Aluminium Titanium Nitride (AlTiN)
Titanium Carbonitride (TiCN)
MOVIC
Effects
Parameters Materials

Tool life (Inches)

Improvement Over TiN

TiN
TiAlN
TiAlN+MOVIC

1000
2400
4000

140%
300%

Through Spindle Air

Good alternative to cutting fluids in case of drilling,

boring, reaming.

Passing air at high pressure through the machine

spindle.

For superior cooling and chip disposal, a very high

pressure is required.

High Speed Machining

Combination of high feed-rate and very high spindle

RPM.

Heat is retained in chip and removed before it can

soak in to work piece.

Operates at low Power

Conventional Machining = 0.25-0.5 Hp/rpm
High Speed Machining = 0.005 hp/rpm

Near Dry Machining (NDM)

Also known as Minimum Quantity Lubrication

Air + oil = Aerosols

Aerosol are generated using the process known as
Atomization.

Advantages of Dry Machining

No coolant or less coolant hence cost reduction.

Does not affect the health of workers.

Reduces pollutants hence enhances environmental

conditions greatly.

Disadvantages of Dry Machining

Not suitable in case of multiple operation in short

period of time.

Industry has not seen its use beyond Cast Iron.

Certain metals like Al still needs high pressure

coolant to prevent Built Up Edge.

Applications of Dry Machining

Die Mould Manufacturing.

General Production such as Gears, crank case,

spindles, crankshaft etc.

Conclusion

Many opportunities to save money and reduce

machining time.

In case of machining hard materials its worth a try.

It wont replace Wet machining but it offers

advantages for economical views and some small
markets.

REFERENCES

O.Cakir, A. Yardimeden, T.Ozben, E. Kilickap ; Department of Mechanical

Engineering, Dicle University,Diyarbakir, Turkey ; Selection of cutting fluids in
machining process

Neil Canter; Head of consulting company Chemical Solutions in Willow Grove,

Pa; Possibilities and Limitations of Dry Machining

M. V. R. D. Prasad, G. Ranga Janardhana and D. Hanumantha Rao ; Experimental

Investigation To Study The Influence Of Process Parameters In Dry Machining

CobaltTungsten Carbide: Powders and Hard Metals ; March 16, 2009 ; U.S.
Department of Health and Human Services, Public Health Service, National
Toxicology Program, Research Triangle Park, NC 27709

Viktor P. Astakhov ; General Motors Business Unit of PSMI, 1255 Beach Ct.
Saline MI 48176, USA; Ecological machining - Near dry machining

Questions
?

Thank You