Thrust force model for vibration-assisted drilling of aluminum 6061-T6

2009 ◽  
Vol 49 (14) ◽  
pp. 1070-1076 ◽  
Author(s):  
Simon S.F. Chang ◽  
Gary M. Bone
Keyword(s):  
Thrust Force ◽  
Force Model

scholarly journals A Force Sensorless Method for CFRP/Ti Stack Interface Detection during Robotic Orbital Drilling Operations

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
Author(s):  
Qiang Fang ◽  
Ze-Min Pan ◽  
Bing Han ◽  
Shao-Hua Fei ◽  
Guan-Hua Xu ◽  
...  
Keyword(s):  
Cutting Force ◽  
Thrust Force ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Reinforced Plastics ◽  
Orbital Drilling ◽  
Drilling Parameters ◽  
Drilling Operations ◽  
Machining Properties

Drilling carbon fiber reinforced plastics and titanium (CFRP/Ti) stacks is one of the most important activities in aircraft assembly. It is favorable to use different drilling parameters for each layer due to their dissimilar machining properties. However, large aircraft parts with changing profiles lead to variation of thickness along the profiles, which makes it challenging to adapt the cutting parameters for different materials being drilled. This paper proposes a force sensorless method based on cutting force observer for monitoring the thrust force and identifying the drilling material during the drilling process. The cutting force observer, which is the combination of an adaptive disturbance observer and friction force model, is used to estimate the thrust force. An in-process algorithm is developed to monitor the variation of the thrust force for detecting the stack interface between the CFRP and titanium materials. Robotic orbital drilling experiments have been conducted on CFRP/Ti stacks. The estimate error of the cutting force observer was less than 13%, and the stack interface was detected in 0.25 s (or 0.05 mm) before or after the tool transited it. The results show that the proposed method can successfully detect the CFRP/Ti stack interface for the cutting parameters adaptation.

Thrust force model for ultrasonic-assisted micro drilling of DD6 superalloy

2022 ◽  
Author(s):  
Xiao-Xiang Zhu ◽  
Wen-Hu Wang ◽  
Rui-Song Jiang ◽  
Yi-Feng Xiong ◽  
Xiao-Fen Liu
Keyword(s):  
Thrust Force ◽  
Force Model ◽  
Ultrasonic Assisted ◽  
Micro Drilling

Surface characteristics and machining performance of TiAlN-, TiN- and AlCrN-coated tungsten carbide drills

2018 ◽  
Vol 233 (4) ◽  
pp. 1075-1086 ◽  
Author(s):  
Chaiya Dumkum ◽  
Pakin Jaritngam ◽  
Viboon Tangwarodomnukun
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Thrust Force ◽  
Surface Characteristics ◽  
Average Error ◽  
Force Model ◽  
Machining Performance ◽  
Coating Materials ◽  
Drilling Performance

This article presents a comprehensive analysis of surface characteristics and drilling performance of uncoated and coated tungsten carbide drills. The single- and double-layer coatings of TiN, TiAlN and AlCrN were examined in terms of surface roughness, microhardness and crack resistance. In addition, drilling torque and thrust force were experimentally measured and compared to the developed models based on the drilling mechanics and drill geometries. Tool wear and hole surface roughness were also considered to assess the machining performance of different coated tools. The results revealed that all coated drills can offer better cut surface quality, 28% lower cutting loads and longer tool life than the uncoated drills. Although AlCrN was found to be the hardest coating material among the others, it caused large wear on the cutting edges and poor surface roughness of produced holes. The lowest torque and thrust force were achievable using TiN-coated drill, while the use of TiAlN coating resulted in the lowest surface roughness and smallest tool wear. Furthermore, the drilling torque and thrust force model developed in this study were found to correspond to the experimental measures with the average error of 8.4%. The findings of this work could facilitate the selection of coating materials to advance the machining performance.

Experimental Study on Orbital Drilling Force and Machining Quality of CFRP

2014 ◽  
Vol 1061-1062 ◽  
pp. 542-549
Author(s):  
Xue Mei Chen ◽  
Qing Liang Chen ◽  
Feng Tao He ◽  
Xi Feng Fan
Keyword(s):  
Thrust Force ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Drilling Force ◽  
Drilling Tool ◽  
Orbital Drilling ◽  
Reinforced Plastic ◽  
Predominant Factor

This paper aims to investigate orbital drilling process in carbon-fiber reinforced plastic (CFRP) composites with multi-point orbital drilling tool based on the robot automatic drilling system. One orthogonal experiment has been carried out, and the cutting forces of different parameters were measured online by dynamometer. Furthermore, the cutting force model was established through regression analysis, and the impacts of cutting parameters on thrust force were deeply analyzed. In addition, delamination and tear defects were inspected respectively, and the relationship between thrust force and delamination and tear was discussed. Our results indicate that thrust force increased with the increasing feed rate and axial feed depth, while decreased with the increasing spindle speed. Axial feed depth was found as the predominant factor on thrust force and defects. At last, the cutting parameters was optimized and then thrust force decreased more than 26% with almost none tear and burr around the hole, which indicates a better machine quality.

Generic Analytical Thrust-Force Model for Flapping Wings

AIAA Journal ◽  
2018 ◽  
Vol 56 (2) ◽  
pp. 581-593 ◽  
Author(s):  
Zongxia Jiao ◽  
Longfei Zhao ◽  
Yaoxing Shang ◽  
Xiaohui Sun
Keyword(s):  
Thrust Force ◽  
Flapping Wings ◽  
Force Model

Research on the Ductile Chip Formation in Grinding of Brittle Materials

2011 ◽  
Vol 487 ◽  
pp. 58-62
Author(s):  
Yun Feng Peng ◽  
Zhi Qiang Liang ◽  
Yong Bo Wu ◽  
Yin Biao Guo ◽  
T. Jiang ◽  
...  
Keyword(s):  
Shear Stress ◽  
Compressive Stress ◽  
Chip Formation ◽  
Thrust Force ◽  
Brittle Materials ◽  
Chip Thickness ◽  
Force Model ◽  
Theoretical Discussion ◽  
Undeformed Chip Thickness ◽  
Formation Zone

A theoretical discussion has been presented for the ductile chip formation in grinding of brittle materials. The single abrasive grit was dealt with a top-rounded cutter removing material of varying undeformed chip thickness. The force model in the chip formation zone was established. The stress analysis showed that larger compressive stress and shear stress can be generated in the chip formation zone, which shields the growth of pre-existing flaws in the material by suppressing the stress intensity factor. When the stress intensify factor is smaller than fracture toughness and the resolved shear stress exceeds the critical flow stress of the material, the ductile chip is formed. Experiments of monocrystal silicon grinding were conducted. The results show that the thrust force is much larger than the cutting force, which ensures the larger compressive stress in the chip formation zone and the formation of ductile chip.

Experimental and Numerical Analysis of the Friction Drilling Process

2006 ◽  
Vol 128 (3) ◽  
pp. 802-810 ◽  
Author(s):  
Scott F. Miller ◽  
Rui Li ◽  
Hsin Wang ◽  
Albert J. Shih
Keyword(s):  
Thrust Force ◽  
Infrared Camera ◽  
Element Model ◽  
Single Step ◽  
Threshold Temperature ◽  
Force Model ◽  
Drilling Process ◽  
Measured Temperature ◽  
Friction Drilling ◽  
Hole Making

Friction drilling is a nontraditional hole-making process. A rotating conical tool is applied to penetrate a hole and create a bushing in a single step without generating chips. Friction drilling relies on the heat generated from the frictional force between the tool and sheet metal workpiece to soften, penetrate, and deform the work-material into a bushing shape. The mechanical and thermal aspects of friction drilling are studied in this research. Under the constant tool feed rate, the experimentally measured thrust force and torque were analyzed. An infrared camera is applied to measure the temperature of the tool and workpiece. Two models are developed for friction drilling. One is the thermal finite element model to predict the distance of tool travel before the workpiece reaches the 250°C threshold temperature that is detectable by an infrared camera. Another is a force model to predict the thrust force and torque in friction drilling based on the measured temperature, material properties, and estimated area of contact. The results of this study are used to identify research needs and build the foundation for future friction drilling process optimization.

scholarly journals Development of a Semi-analytical Dynamic Thrust Force Model

2021 ◽  
Author(s):  
Marin Akter ◽  
Mohammad Abdul Alim ◽  
Md Manjurul Hussain ◽  
Kazi Shamsunnahar Mita ◽  
Anisul Haque ◽  
...  
Keyword(s):  
Water Mass ◽  
Stokes Equations ◽  
Thrust Force ◽  
Variational Iteration Method ◽  
Navier Stokes ◽  
Force Model ◽  
Dynamic Force ◽  
Navier Stokes Equations ◽  
Cyclone Sidr ◽  
Saint Venant Equations

Abstract A moving water mass generates force which is exerted on its moving path. Cyclone generated storm surge or earthquake generated tsunami are specific examples of moving water mass the generates force along the coasts. In addition to human lives, these moving water masses cause severe damages to the coastal infrastructure due to tremendous force exerted on these structures. To assess the damage on these infrastructures, an essential parameter is the resultant force exerted on these structures. To evaluate the damages, there is hardly any quantitative method available to compute this force. In this paper we have developed a semi-analytical model, named as Dynamic Force Model (DFM), by using Variational Iteration Method to compute this force. As governing equations, we have used the Saint Venant equations which are basically 1D shallow water equations derived from the Navier-Stokes equations. The verified, calibrated and validated DFM is applied in Bangladesh coastal zone to compute dynamic thrust force due to tropical cyclone SIDR.

Investigation on thrust force in rotary ultrasonic drilling of CFRP/aluminum stacks

2019 ◽  
Vol 234 (2) ◽  
pp. 394-404
Author(s):  
Song Dong ◽  
Wenhe Liao ◽  
Kan Zheng ◽  
Wenrui Ma
Keyword(s):  
Theoretical Model ◽  
Thrust Force ◽  
Chip Thickness ◽  
Machining Process ◽  
Aviation Industry ◽  
Force Model ◽  
Drilling Process ◽  
Ultrasonic Drilling ◽  
Thrust Forces ◽  
Rotary Ultrasonic Drilling

The stacks of carbon fiber-reinforced polymer (CFRP) and aluminum are widely used in aviation industry due to its excellent mechanical and physical properties. Recently, rotary ultrasonic drilling technology which is recognized as a useful machining method has been introduced to machining these stacks. Thrust force influences the machinability directly such as tool wear, cutting temperature, and hole qualities. In this study, a theoretical model of thrust force for rotary ultrasonic drilling of CFRP/aluminum stacks is proposed. Based on the analysis of kinematic characteristics, the axial uncut chip thickness of rotary ultrasonic drilling is presented. Then the whole machining process of stacks is divided into five different states. Forces on cutting edge and chisel edge in different materials are modeled, respectively. After that, the thrust forces of five-state rotary ultrasonic drilling process are achieved by integrating with integral limits analysis in each state. Finally, verification experiments are conducted, and experimental results show that the trends of thrust forces agree well with the thrust force model. Therefore, this theoretical model can be used to evaluate the thrust force in rotary ultrasonic drilling of CFRP/aluminum stacks.

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