Development and Evaluation of Near-Dry Machine Tools for the Production of Aluminum Components – Phase I and II
NCMS Project #: 150320
Problem:
- Determine technical and economic benefits of wet vs. dry methods of machining cast aluminum alloy 308 automotive components.
- Determine cost savings from wet vs. dry drilling, milling, reaming, and tapping aluminum 308.
Benefit:
- Availability:
- Machine tools shall require design optimization for NDM
- Machine tool technology is now available that can be bundled with NDM technology
- Cost: An 8.5% cost per part reduction may be realized
- Reliability:
- Failure modes and downtime associated with coolant would be eliminated
- Maintenance and repair associated with coolant would be eliminated
- Cycle Time: Same as WET process
Solution/Approach:
- Replace the conventional high-pressure coolant process – the WET process using near-dry-machining (NDM) and minimum quantity lubrication (MQL) process.
- Provide test results showing that the production rate and quality of the parts produced using the NDM process are equivalent to the current WET process.
- Provide quality, cost, and production data produced during the pilot study to conclude that NDM technology is implementation-ready for the operations of drilling, milling, reaming, and tapping in aluminum alloy 308.
DOD Participation:
- U.S. Air Force (Warner Robins Air Logistics)
- U.S. Navy (Fleet Readiness Center East)
Industry Participation:
- DaimlerChrysler Corporation
- Ford Motor Company
- General Motors Corporation
- Horkos Corp.
- Kennametal IPG
- Marubeni America Corporation
- Manufacturing Enterprises, Inc.
- Ex-Cell-O Machine Tools, Inc.
- NCMS