Dry and minimum quantity lubrication drilling of cast magnesium alloy (AM60)

Dry and minimum quantity lubrication (MQL) drilling of cast magnesium alloy AM60 used in the manufacturing of lightweight automotive components have been studied. The maximum and average torque and thrust forces measured during drilling using distilled water (H₂O-MQL) and a fatty acid-based MQL fluid (FA-MQL), both supplied at the rate of 10 ml/h, were compared with those generated during flooded (mineral oil) drilling. Tool life during dry drilling was inadequately short, due to excessive magnesium transfer and adhesion to the (HSS steel) drill causing drill failure in less than 80 holes. The use of MQL reduced magnesium adhesion and built-up edge formation, resulting in an increase in tool life as well as reductions in both average torque and thrust forces—prompting a performance similar to that of flooded drilling. The maximum temperature generated in the workpiece during MQL drilling was lower than that observed in dry drilling, and comparable to flooded condition. The mechanical properties of the material adjacent to drilled holes, as evaluated through plastic strain and hardness measurements near the holes, revealed a notable softening in the case of dry drilling, but not for MQL drilling. MQL drilling provided a stable drilling performance, which was evident from the uniform torque and force patterns throughout the drilling cycles and also resulted in desirable machining characteristics, including a smooth hole surface and short chip segments.