The Development and Evaluation of Near-Dry Machine Tools for the Production of Aluminum Components—Phase II (Near-Dry)

Final Report of NCMS Project No. 150320b

This report summarizes the second of the two-phase project whose objective was to evaluate the achievable benefits from an advanced near-dry production machining process. Machining Enterprises, Inc. (MEI), a parts manufacturer for the automotive industry, piloted the first phase of the program by machining 30,000 GM engine brackets. Data from this pilot project established the technical and economic feasibility for using near-dry technology in a U.S. factory. In comparison to a conventional process incorporating high-pressure coolant delivered through the spindle, the near-dry process was determined to be 8.5% less expensive - even without taking into account the costs of eliminating a central coolant treatment facility as well as the costs of dealing with coolant-related health issues.