# I. Introduction & Literature Review Anderson & Whitcomb (2016) defined Minimum Quantity Lubrication (MQL) as the use of cutting fluids of only a minute amount-typically of a flow rate of 50-500 ml/hour-which is about three to four orders of magnitude lower than the amount commonly used in flood cooling. The concept of Minimum Quantity Lubrication (MQL), sometimes referred to as near dry lubrication 'or micro lubrication (Asad, Girardin, Mabrouki & Rigal, 2008). A large amount of heat is generated in dry machining because of rubbing between the cutting tool and workpiece. The application of cutting fluid during machining operation reduces cutting zone temperature and increase tool life yet it causes skin and lung disease to the operators and air pollution (Ezugwu & Lai, 1995;Beaubien & Cattaneo, 1964). Ahsan, Kibria, Ahmed, Islam & Hossain (2010) found that MQL generally uses vegetable oil or ester oil as the cutting fluid. These high-performing oils have excellent lubrication and natural dissolving properties. This result avoids pollution of the environment and related problems of health and safety, and drastically reduces lubricant costs (Khan, Mithu & Dhar, 2009), although it may cause problems of corrosion (Kirkaldy & Young, 1987). Furthermore, they are environmentally friendly (Khan, Mithu & Dhar, 2009). In our study, Diod sol-M is used as a lubricant. According to a survey conducted by the European Automobile Industry, the cost incurred on lubricants comprises nearly 20% of the total manufacturing cost. The cost of the cutting tool is only 7.5% of the total cost (Brockhoff & Walter, 1998). Braga, Diniz, Miranda, & Coppini (2002) compared the performances of the uncoated and diamond coated carbide drills, using minimal lubrication (10 ml/h of oil in a flow of compressed air) and abundant soluble oil as a refrigerant/lubricant in the drilling of aluminum-silicon alloys (A356). In the experiments cutting speeds of 10-50 m/min and feed of 0.1-0.2 mm were used. The lubrication was applied either with an external nozzle or internally through the drill. It was concluded that the measured temperature with the application of MQL internally through the tool was 50% smaller than those obtained with MQL applied with an external nozzle. When MQL was applied with an external nozzle the greatest temperature was measured in a piece drilled with an uncoated drill. For different coatings, there was no significant variation in temperature (Zeilmann & Weingaertner, 2006). A study was conducted at Georgia Institute of Technology to compare the mechanical performance of minimum quantity lubrication over J completely dry lubrication for the turning of hardened rilling is the operation of cutting a hole of circular cross-section in solid materials using a drill bit. The drill bit is usually a rotary cutting tool, often multipoint. The drill bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute. A drilling machine comes in many shapes and sizes, from small hand-held power drills to bench mounted and finally floor-mounted models. They can perform operations other than drilling, such as countersinking, counterboring, ream, and tap large or small holes (Eskicioglu & Davies, 1983; Kibbe, White, Meyer, Curran, & Stenerson, 2014; Lemelson, 1967). # D A36) Abstract-This study is conducted to analyze the performance of Mild Steel (ASTM A36) using a drill bit (8.25mm &10.25mm high-speed steel) at two different speeds (270 & 630 RPM) under the three conditions (Dry, MQL, and Wet). The Taguchi has been introduced to find out the most influential factors and most of the cases it was drilling conditions. This performance study has been accelerated by using minitab18 software for ANOVA analysis. Thus it gives the clear indication about the effects of RPM, drilling conditions and drill bit size on drilling a particular materials MS (ASTM A36). The conditions and factors have been shown whether it is statistically significant and how much. One conspicuous thing that the interaction between conditions and factors also have the significant effect. The wet cooling condition has shown the better performance on surface roughness for all conditions and drill bit size. The drilling under wet cooling and MQL conditions have almost the same results but it varies in the case of the dry condition. Low RPM is found to be statistically significant than it is for high RPM. The regression line equation can bring the remarkable significance of further drilling Mild Steel at any drilling conditions. bearing-grade steel materials with low content CBN cutters (Liang & Ronan, 2003). A series of MQL drilling tests were conducted to determine if a high penetration rate could be achieved under oil delivery rate was 50 ml/hr, Air pressure for all tests was 4.96 bars, and air consumption was approx. 31 l/min. It was concluded that MQL process costs were approximately 10% lower than the traditional machining process. Dry chips were produced and could have been sold to a recycling facility without additional processing. Air quality for MQL was better than conventional machining, with a significant reduction in aerosol particle concentration (Filipovic & Stephenson, 2006). Taguchi method analyzes the influence of parameter variation on response characteristics. Thereby, and an optimal result can be obtained from the sensitivity analysis respect to parameter variation. However, Taguchi method has shown some defects in dealing with the problems of multiple performance characteristics (Bement, 1989 The lubricating agent needs to be supplied at high pressure and impinged at high speed through the nozzle at the cutting zone under MQL condition. Considering the requirements for the present work and uninterrupted supply of MQL at constant pressure, an MQL delivery system has been designed and fabricated. The thin but high-velocity stream of MQL was projected in such a direction so that the coolant could reach as close to the chip-tool and the work-tool interfaces as possible. # III. Data Analysis And Interpretation The data obtained from the experimental investigation are analyzed with two statistical tools Taguchi and ANOVA. All collected data were recorded using Microsoft Excel and transferred to Minitab 17 4.1 shows the effect of cutting condition, cutting speed and their interaction on surface roughness. For speed the null hypothesis is accepted, that is, there is no statistically significant difference in the mean between the different groups of independent variables. But for the condition the null hypothesis is rejected, that is, there is a statistically significant difference in the mean between the different groups of independent variables. The interaction effect is not statistically significant. That is, the effect of cooling condition on surface roughness is not dependent on cutting speed (and vice versa). The surface roughness analysis of variance results for drilling mild steel with 10. 25 4.2 shows the effect of cutting condition, cutting speed and their interaction on surface roughness. For the speed and conditions the null hypothesis is rejected, that is, there is a statistically significant difference in the mean between the different groups of independent variables. The interaction effect is not statistically significant. That is, the effect of cooling condition on surface roughness is not dependent on cutting speed (and vice versa). V. The performance of MS (ASTM A36) is highlighted in a graphical manner to aid the analysis. The correlation analysis for surface roughness has been shown with respect to the no. of holes drilled under varying drilling conditions. The graphical results support as the results found in both Taguchi and ANOVA. # Graphical Analysis From Fig. 5.1 Main effects and Interaction effects plot for S/N Ratio, it has been seen that the in the wet condition the roughness is better than the MQL and dry respectively. Here the drilling conditions are the most influential factors than RPM and Feed. Also, the high feed and low RPM is better for surface roughness. Performance measure on MQL and wet machining have almost the same results. From Fig. 5.2 Main effects and Interaction effects plot for surface roughness, it has been noticed that For 8.25 mm drill bit, Surface roughness varies in the range of 3.034 to 3.962 mm for dry machining. Surface roughness varies in the range of 2.565 to 3.596 mm for MQL machining. Surface roughness varies in the range of 2.458 to 3.47 mm for flood machining. It can be seen from the graph that surface roughness for MQL machining is closer to flood machining than dry machining. For 10.25 mm drill bit, Surface roughness varies in the range of 2.940 to 3.909 um for dry machining. Surface roughness varies in the range of 2.552 to 3.021 mm for MQL machining. Surface roughness varies in the range of 2.425 to 2.898 mm for flood machining. It can be seen from the graph that surface roughness for MQL machining is closer to flood machining than dry machining. # VI. # Findings Taguchi, ANOVA, and graphical analysis results under varying drilling conditions, Drill bit size and RPM are: a) Drilling conditions are the most influential factor b) Wet machining condition is better for surface roughness c) Low rpm (270 rpm) is better for surface roughness d) For 8.25mm drill bit, the speed, conditions, and interaction effect are not statistically significant that is there is no statistically significant difference in the mean between the different groups of independent variables. e) For 10.25mm drill bit, the speed and conditions have statistical significance but interaction effect is not statistically significant. f) Performance measure on MQL and wet machining have almost the same results. VII. # Conclusion at varying drilling conditions, drill bit size and RPM is very useful research work in the field of manufacturing. Statistical tools Taguchi, ANOVA are used to analyze the performance of surface roughness under varying conditions and factors. Drilling conditions are found to be most influential factors rather than drill bit size and RPM. Wet machining conditions and low RPM is better for surface roughness. This research work will help to ![; Roy, 2001; Berginc, Kampus & Sustarsic, 2006; Kopa?, Bahor & Sokovi ?, 2002; Li & Hong, 2005; Ming -der & Yih-fong, 2004; Grzesik, Rech, & Wanat, 2006). Further, design optimization for quality was carried out and signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were employed using experimental results to confirm the effectiveness of this approach (Yang & Tarng 1998; Islam et al., 2015). The main objective of this paper is to analyze the performance of mild steel (ASTM II. Experimental Setup With Working Principle In this study lubricant and the air is mixed by MQL setup which is based on spray gun concept. The two separate hollow pipes carry lubricant and air which mixed in mixing chamber just before the tip of the nozzle. The lubricant flow is controlled by the knob. In order to have contentious mist, constant pressure is assured by the pressure gauge reading because the change in pressure may vary the quantity of the lubricant coming out of the nozzle. The developed MQL system consists of four major parts (a) compressor (b) lubricating Oil reservoir (c) Mixing chamber (d) Nozzle](image-2.png "") ![(a) MQL set up (b) Operation performing on MQL](image-3.png "") 1![Figure 1: Photographic view of MQL set up and an operation performing on MQL.](image-4.png "Figure 1 :") 51![Fig. 5.1: Main effects and Interaction effects plot for S/N Ratio](image-5.png "Fig. 5 . 1 :") 31Year 20188( ) Volume XVIII Issue III Version IGlobal Journal of Researches in EngineeringJ© 2018 Global Journals statistical software for the ANOVA analysis. Before ANOVA analysis the normality test has been performed to check whether the data is normal & fit for the ANOVA analysis. A36) under varying drilling conditions. 32 33S/N response (Drill bit: 8.25mm)Mean response (Drill bit: 8.25mm)LevelCondition's (Dry, MQL ,Wet)RPM (270 & 630 rpm)Feed (mm/rev)Condition's (Dry, MQL ,Wet)RPM (270 & 630 rpm)Feed (mm/rev)1-11.212-10.095-9.9913.6463.2303.1802-9.603-10.170-10.2733.0433.2473.2973-9.5823.026Year 2018Delta Rank1.630 10.075 30.282 20.62 10.017 30.117 210J ( ) Volume XVIII Issue III Version ILevel 1 2 3 DeltaS/N response (Drill bit: 10.25mm) Condition's (Dry, MQL ,Wet) RPM (270 & 630 rpm) Feed (mm/rev) -10.702 -9.370 -9.991 -9.037 -9.799 -10.273 -9.014 1.688 0.429 2.313Mean response (Drill bit: 10.25mm) Condition's (Dry, MQL ,Wet) RPM (270 & 630 rpm) Feed (mm/rev) 3.437 2.961 3.022 2.833 3.106 3.044 2.830 0.607 0.145 0.022Global Journal of Researches in EngineeringIV. Rank a) ANOVA Assumptions Anova Analysis 2 311 b) ANOVA Hypothesis 1. Null Hypothesis: There is no significant difference 2 3 between the responses obtained by varying the individual input variables. 2. Alternate Hypothesis: There is a significant difference between the responses obtained by varying the individual input variables. c) ANOVA Results For ease of use, the following factors have been coded as below when used in Minitab. Dry: Coded as 11 MQL: Coded as 12 Wet: Coded as 131. Individual differences and errors of measurement are normally distributed within each group.270 RPM: Coded as 1 630 RPM: Coded as 22. Size of the variance and distribution of individualdifferences and random errors are identical in eachgroup.3. Individual differences and errors of measurementare independent of the group to group.© 2018 Global Journals 41 TableAnalysis of VarianceSourceDFAdjustedAdjustedF-ValueP-ValueSSMSSpeed10.01630.016300.240.623Condition215.38697.69346114.420.000Speed*Condition20.11350.056750.840.432Error17411.69900.06724Total17927.2158Model SummarySR-sqR-sq(adj) R-sq(pred)0.259299 57.01%55.78%54.00%CoefficientsTermCoefSE Coef T-Value P-Value VIFConstant3.1936 0.0193165.24 0.000Speed1-0.0095 0.0193-0.490.6231.00Condition110.4083 0.027314.940.0001.3312-0.1474 0.0273-5.390.0001.33Speed*Condition1 110.0110 0.02730.400.6871.331 12-0.0347 0.0273 -1.270.2051.33Regression EquationRa = 3.1936 -0.0095 Speed_1 + 0.0095 Speed_2 + 0.4083 Condition_11 -0.1474 Condition_12-0.2608 Condition_13 + 0.0110 Speed*Condition_1 11 -0.0347 Speed*Condition_1 12+ 0.0237 Speed*Condition_1 13 -0.0110 Speed*Condition_2 11 + 0.0347 Speed*Condition_212 -0.0237 Speed*Condition_2 13Fits and Diagnostics for Unusual ObservationsObs.RaFitResid.Std. Resid.21 3.0340 3.6034 -0.5694 -2.23 R30 2.9780 3.6034 -0.6254-2.45 R33 3.5960 3.0019 0.59412.33 R62 3.4700 2.9470 0.52302.05 R150 3.6720 3.0904 0.58162.28 R179 3.5330 2.9186 0.61442.41 RR Large residual 42General Linear Model: Ra versus Speed, ConditionYear 2018Analysis of Variance Source DFAdjusted SSAdjusted MS F-ValueP-Value12Speed11.61821.6182444.590.000J ( ) Volume XVIII Issue III Version I Global Journal of Researches in EngineeringCondition Speed*Condition 2 2 Error 174 Total 179 Model Summary S R-sq R-sq(adj) R-sq(pred) 19.4964 0.1675 6.3147 27.5968 0.190503 77.12% 76.46% 75.51% Coefficients Term Coef SE Coef T-Value P-Value VIF 9.74819 268.61 0.08374 2.31 0.03629 Constant 3.0778 0.0142 216.76 0.000 Speed 1 -0.0948 0.0142 -6.68 0.000 1.00 Condition 11 0.4598 0.0201 22.90 0.000 1.33 12 -0.1676 0.0201 -8.34 0.000 1.33 Speed*Condition 1 11 0.0426 0.0201 2.12 0.035 1.33 1 12 -0.0273 0.0201 -1.36 0.176 1.33 Regression Equation Ra = 3.0778 -0.0948 Speed_1 + 0.0948 Speed_2 + 0.4598 Condition_11 -0.1676 Condition_12 0.000 0.103 -0.2923 Condition_13 + 0.0426 Speed*Condition_1 11 -0.0273 Speed*Condition_1 12 -0.0153 Speed*Condition_1 13 -0.0426 Speed*Condition_2 11 + 0.0273 Speed*Condition_2 12 + 0.0153 Speed*Condition_2 13 Fits and Diagnostics for Unusual Observations Obs. Ra Fit Resid Std Resid 5 3.0070 3.4854 -0.4784 -2.55 R 21 3.9090 3.4854 0.4236 2.26 R232.9400 3.4854-0.5454-2.91 R273.0900 3.4854-0.3954-2.11 R923.1680 3.5898-0.4218-2.25 R1123.1950 3.5898-0.3948-2.11 R1203.1150 3.5898-0.4748-2.54 RR Large residual© 2018 Global Journals Performance Analysis of Mild Steel (ASTM A36) Under Varying Drilling Conditions UsingTaguchi and ANOVA © 2018 Global Journals * DOE Simplified: practical tools for effective experimentation MJAnderson PJWhitcomb 2016 CRC Press * Dry cutting study of an aluminum alloy (A2024-T351): a numerical and experimental approach MAsad FGirardin TMabrouki JFRigal International Journal of Material Forming 1 1 2008 * Failure modes and wear mechanisms of M35 high-speed steel drills when machining Inconel 901 EOEzugwu CJLai Journal of materials processing technology 49 3-4 1995 * A study of the role of cutting fluid in machining operations SJBeaubien AGCattaneo Lubrication Engineering 10 1964 * Performance evaluation of minimum quantity lubrication (MQL) in the drilling operation NM MAhsan GMKibria RMAhmed AMIslam MMHossain International Conference on Mechanical, Industrial and Energy Engineering 2010. 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