Single-Stroke Rotary Deep Hole Drilling of Stainless Steel Using Low-Pressure Nano-Fluid Lubrication
Corresponding author: Ky-Thanh Ho
Abstract
This study demonstrates a novel, low-cost lubrication technique that enables single-stroke deep hole drilling of SUS 304 stainless steel using a rotary twist drill with internal coolant channels. A graphene-based nanofluid, formulated by dispersing graphene nanosheets into a water-soluble emulsion and diluted with tap water, was internally delivered at low pressure (1.5 bar) and low flow rate (0.25 L/min). Comparative trials under varying cutting conditions (spindle speeds: 430–870 rev/min and feed rates: 0.04–0.10 mm/rev) revealed that drilling with the proposed nanofluid produced chips with favorable morphology and manageable length, facilitating efficient evacuation. In contrast, conventional emulsion generated crushed chips prone to clogging. The graphene-based nanofluid also significantly reduced the thrust force and extended the tool life, enabling stable deep-hole drilling without pecking or tool failure. Statistical analysis and Taguchi optimization confirmed the robustness of the proposed approach. Unlike high-pressure or ultrasonic-assisted systems, the proposed method offers a simple and energy-efficient solution for machining hard-to-cut materials under realistic manufacturing conditions.
Keywords:
nano-fluid, deep hole drilling, hard-to-cut materials, thrust force, tool wearDownloads
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