Development and Evaluation of Near-Dry Machine Tools for the Production of Aluminum Components – Phase I and II

NCMS Project #: 150320


  • 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.


  • 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


  • 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

Final Report

Final Report