The Drilling Fluids Selection in the Deep-Hole Drilling, Reaming and Tapping Process
Abstract
The deep hole drilling, reaming and tapping processes used in manufacturing are crucial operations that require selecting the right cutting fluid. This paper discusses the various types of fluids available, their respective properties, and their proper applications in the deep hole drilling, reaming and tapping processes. Recommendations are given for cutting fluids with the best performance.
Introduction
The manufacturing of components involves many processes with various cutting and machining operations; among them, deep hole drilling is one of the most important. This process typically involves the use of long, straight fluted drills with coolant passing through them to facilitate the cutting process. Furthermore, reaming and tapping can be used in combination with drilling to produce accurate holes with smoother surfaces.
The selection of a cutting fluid for the deep-hole drilling, reaming and tapping processes is critical for producing the desired results. Different types of fluids are available including mineral oil-based, water miscible and synthetic varieties, each with different properties. As such, it is important to determine which cutting fluid is best suited for a particular application in order to achieve optimal performance.
Types of Cutting Fluids
Mineral oil-based cutting fluids are the most commonly used products in the industry. They are composed of a mineral oil emulsion combined with an emulsifier as well as other additives. Mineral oil-based fluids provide excellent lubrication and cooling capacity which makes them ideal for the deep hole drilling, reaming and tapping processes.
Water miscible fluids are designed to be mixed with water to form a cutting fluid that can be used in these processes. These fluids are primarily composed of an organic base such as glycol or polyether and contain emulsifiers and other additives.
Water miscible fluids provide good lubrication, cooling capacity, and chip evacuation and have proven to be suitable for operations involving high-speed tools due to their ability to:
o Split the chips into small pieces
o Evacuate them quickly and efficiently
Synthetic fluids are also available and are similar in composition to water miscible fluids. Synthetic fluids are more suitable for operations involving materials with high corrosion resistance, such as stainless steel, as they are more tolerant to elevated temperatures than their mineral oil-based counterparts.
Advantages of Cutting Fluids
Cutting fluids have numerous advantages that make them essential in the deep hole drilling, reaming, and tapping process. Most notably, these fluids provide the following:
o Improved tool life due to their cooling capacity, which reduces wear and tear on the cutting tool
o Better surface finish as the lubrication that the fluid provides can result in a smoother finish compared to dry cutting
o Enhanced chip evacuation due to the addition of wetting agents that help break up and evacuate the chips efficiently
o Increased speeds and feeds as compared to dry cutting due to their lubricating properties
Helpful Tips
It is important to select the right cutting fluid for the job; however, the selection process can be challenging. It is recommended that a qualified engineer should be consulted for optimization of the machining processes, including the selection and use of cutting fluids. Furthermore, careful monitoring of the cutting fluid should be conducted to ensure that the products performance remains optimal.
Conclusion
The deep hole drilling, reaming and tapping processes require the use of cutting fluids as they provide enhanced performance and improved quality. Various types of cutting fluids are available, each with their own properties, and careful consideration needs to be taken when selecting the right fluid for a particular application. In conclusion, the best cutting fluid should be selected to optimize cutting performance and tool life.
