Drilling CFRP Laminates by Dual-Axis Grinding Wheel System With Copper/Diamond Functionally Graded Grinding Wheel

2018 ◽  
Vol 140 (7) ◽  
Author(s):  
Takahiro Kunimine ◽  
Hideaki Tsuge ◽  
Daisuke Ogawa ◽  
Motoko Yamada ◽  
Hisashi Sato ◽  
...  
Keyword(s):  
Thrust Force ◽  
Three Dimensional ◽  
Chip Morphology ◽  
Force Sensor ◽  
Functionally Graded ◽  
Grinding Wheel ◽  
Drilling Process ◽  
Low Thrust ◽  
Hole Quality ◽  
Cfrp Laminates

This study aims to investigate the drilling performance of a copper/diamond functionally graded grinding wheel (FGGW) fabricated by centrifugal sintered-casting for carbon fiber-reinforced plastic (CFRP) laminates by originally designed dual-axis grinding wheel (DAGW) system. The copper/diamond FGGW was also originally designed and fabricated by the centrifugal sintered-casting to suppress abrasive-grain wear and reduce the consumption of abrasive grains in our previous study. Drilling tests were carried out over 50 holes in dry machining. Thrust force was evaluated with force sensor during drilling test. Hole diameter, roundness, and roughness were measured to assess hole quality. Drill chips were observed by scanning electron microscope (SEM) to investigate chip morphology. Precision drilling without burring and delamination was achieved in CFRP laminates. Good hole-quality was still obtained over 50 holes due to the low thrust force during drilling. Specific three-dimensional (3D) drilling process of the DAGW system enabled stable and precision drilling with low thrust force in CFRP laminates continuously.

Drilling Force and Chip Morphology in Drilling of PCB Supported Hole

2011 ◽  
Vol 188 ◽  
pp. 429-434 ◽  
Author(s):  
L.P. Yang ◽  
Li Xin Huang ◽  
Cheng Yong Wang ◽  
L.J. Zheng ◽  
Ping Ma ◽  
...  
Keyword(s):  
Feed Rate ◽  
Printed Circuit Board ◽  
Thrust Force ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Circuit Board ◽  
Drilling Process ◽  
Drilling Force ◽  
Drill Bits

Supported holes of Printed circuit board (PCB) are drilled with two different drill bits. Drilling force (thrust force and torque) and chip morphology are examined at different cutting parameters, and the effects of the two drills are discussed. The results indicate that the drilling force and chip morphology are affected by the feed rate, spindle speed and drill shape. Thrust force increases with the increasing feed rate, and decreases with the increasing spindle speed. Optimization of drill geometry can reduce the thrust force significantly, and is effective in chip breaking which can improve the chip evacuation during the drilling process.

scholarly journals An Investigation of the Effect of Parameters and Chip Slenderness Ratio on Drilling Process Quality of AISI 1050 Steel

2018 ◽  
Vol 2018 ◽  
pp. 1-9 ◽  
Author(s):  
Zülküf Demir ◽  
Rifat Yakut
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Thrust Force ◽  
Slenderness Ratio ◽  
Chip Morphology ◽  
Drilling Process ◽  
Steel Alloy ◽  
Drilling Operations ◽  
Machining Operations

The chip slenderness ratio is a vital parameter in theoretical and applicable machining operations. In predrilled drilling operations of AISI 1050 steel alloy, HSS drills were employed, and the effect of the selected parameters on the chip slenderness ratio and also the effect of the chip slenderness ratio on the thrust force, surface roughness, drilled hole delamination, tool wear, and chip morphology were investigated. The major parameters, influential on the chip slenderness ratio, were feed rate and point angle, while spindle speed was too small to be negligible. With increasing the chip slenderness ratio, the thrust force and the tool wear decreased, which resulted in appropriate chip morphology, but there were increases in surface roughness. However, the chip slenderness ratio had no effect on the drilled hole delamination.

scholarly journals Self-Localization of Tethered Drones without a Cable Force Sensor in GPS-Denied Environments

Drones ◽  
2021 ◽  
Vol 5 (4) ◽  
pp. 135
Author(s):  
Amer Al-Radaideh ◽  
Liang Sun
Keyword(s):  
Original Problem ◽  
Pulse Width Modulation ◽  
Thrust Force ◽  
Three Dimensional ◽  
Force Sensor ◽  
Tension Force ◽  
Cable Tension ◽  
Inertial Measurement ◽  
Cable Force ◽  
Measurement Units

This paper considers the self-localization of a tethered drone without using a cable-tension force sensor in GPS-denied environments. The original problem is converted to a state-estimation problem, where the cable-tension force and the three-dimensional position of the drone with respect to a ground platform are estimated using an extended Kalman filter (EKF). The proposed approach uses the data reported by the onboard electric motors (i.e., the pulse width modulation (PWM) signals), accelerometers, gyroscopes, and altimeter, embedded in the commercial-of-the-shelf (COTS) inertial measurement units (IMU). A system-identification experiment was conducted to determine the model that computes the drone thrust force using the PWM signals. The proposed approach was compared with an existing work that assumes known cable-tension force. Simulation results show that the proposed approach produces estimates with less than 0.3-m errors when the actual cable-tension force is greater than 1 N.

Feed rate control in robotic bone drilling process

2020 ◽  
pp. 095441192097589
Author(s):  
Tony Boiadjiev ◽  
George Boiadjiev ◽  
Kamen Delchev ◽  
Ivan Chavdarov ◽  
Roumen Kastelov
Keyword(s):  
Rate Control ◽  
Feed Rate ◽  
Control Algorithm ◽  
Force Sensor ◽  
Sensor Data ◽  
Drilling Process ◽  
Drill Bit ◽  
Bone Drilling ◽  
Hole Quality ◽  
Rate Control Algorithm

The bone drilling process is characterised by various parameters, the most important of which are the feed rate (mm/s) and the drill speed (rpm). They highly reflect the final effects and results of the drilling process, such as mechanical and thermal damages of bone tissue and hole quality. During manual drilling, these parameters are controlled by the surgeon based on his practical skills. But automatic drilling can assure an optimal result of the manipulation where such parameters are under control. During bicortical automatic bone drilling such a process consists of several stages: searching the contact with the first cortex, cortex drilling and automatic stop; searching the contact with the second cortex, cortex drilling and automatic stop; drill bit extraction. This work presents a way to control the feed rate during different stages of the bone drilling process (an original feed rate control algorithm) using the orthopaedic drilling robot (ODRO). The feed rate control is based on a proposed algorithm created and realised by specific software. During bicortical bone drilling process the feed rate takes various values in any stage in the range 0.5–6 mm/s. These values depend on drill bit position and real time force sensor data. The novelty of this work is the synthesis of an original feed rate control algorithm to solve the main problems of bone drilling in orthopaedic surgery – minimisation the drilling time (the heat generation); eliminating of the drill bit slip at the first (near) cortex and the drill bit bending at the second (far) cortex; minimising the risk of micro cracks which causes Traumatic Osteonecrosis; improving hole quality of the drilled holes; eliminating of the drill bit slip and the drill bit bending at the second cortex; minimising the value of the second cortex drill bit penetration by bicortical bone drilling.

A Study of the Drilling Process

1974 ◽  
Vol 96 (4) ◽  
pp. 1207-1215 ◽  
Author(s):  
R. A. Williams
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Three Dimensional ◽  
Drilling Process ◽  
Two Dimensional ◽  
Twist Drill ◽  
Feed Velocity ◽  
Cutting Geometry ◽  
Drill Point ◽  
Finite Thrust

Drilling is a complex three dimensional cutting process yet it is possible to simulate the action of a two flute twist drill with two dimensional models provided consideration is given to the influence of the feed velocity on the cutting geometry at the drill point. Two models of chip formation and an indentation model are developed to simulate the action of the drill point. From these models equations are derived for the prediction of total torque and thrust given the cutting conditions, drill geometry, and an empirical factor which is related to the work material. Computed values of torque and thrust are shown to compare favorably with those obtained from drilling tests on an 0.45 percent C steel. The shape and magnitude of the wear zone about the chisel edge is estimated and it is shown that the observed finite thrust force as the feed rate approaches zero can be attributed to the “cutting” action of the chisel edge.

Finite Element Analysis on Drilling of Unidirectional Carbon Fiber Reinforced Plastic (CFRP)

2013 ◽  
Vol 455 ◽  
pp. 228-231 ◽  
Author(s):  
Yan Li He ◽  
Guo Peng Zhang ◽  
Jun Peng Xue
Keyword(s):  
Finite Element ◽  
Carbon Fiber ◽  
Thrust Force ◽  
Three Dimensional ◽  
Failure Behavior ◽  
Drilling Process ◽  
Fe Model ◽  
Fiber Reinforced ◽  
Element Analysis ◽  
Carbon Fiber Reinforced

Various kinds of damage may occur during the drilling of carbon fiber reinforced polymer composite (CFRP). To review the mechanism of CFRP drilling, a three-dimensional macro-mechanical finite element (FE) model was constructed for CFRP drilling based on FE software tool Abaqus. The workpiece was modeled as equivalent homogenous anisotropic material (EHAM) with elastic-failure behavior. Three-dimensional Hashin criterion was used to predict the material failure. The material was implemented in user subroutine VUMAT. The drilling process was analyzed and the thrust force with respect to cutting conditions was evaluated. The simulation shows that thrust force increase with feed rates while decrease with spindle speed, as agrees with experiment.

Fabrication and Optimization of Drilling Parameters in Heat Treated SiC Reinforced Functionally Graded Al Composites Using Taguchi Method

2012 ◽  
Vol 710 ◽  
pp. 353-358
Author(s):  
K. Vinoth Babu ◽  
J.T. Winowlin Jappes ◽  
T.P.D. Rajan
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Thrust Force ◽  
Functionally Graded ◽  
Drilling Process ◽  
Sic Particles ◽  
Drilling Parameters ◽  
Heat Treated ◽  
Outer Periphery ◽  
Coated Carbide

The present investigation is on the fabrication of SiC particles reinforced aluminum functionally graded disc and optimization of drilling process parameters using Taguchi method. The primary processing of A356-20%SiCpcomposite have been carried out by liquid metal stir casting technique followed by centrifugal casting leading to the formation of a functionally graded Al FGM disc with SiC particles segregating towards the outer periphery of the casting. The composite specimens are heat treated and used for the drilling studies. Taguchi method has been used to find the optimal drilling parameters for surface roughness and thrust force during drilling. The Taguchi Orthogonal arrays, signal-to-noise ratio (S/N) and Analysis of variance (ANOVA) are employed to study the performance characteristics in drilling operations of FGMMC using TiAlN coated carbide tools. The drilling parameters like cutting speed, feed and point angle in three different zones (15, 45, and 75 mm from the outer periphery) of FGMMC are optimized with considerations of surface roughness and thrust force.

scholarly journals Performance Analysis of Multi-Spindle Drilling of Al2024 with TiN and TiCN Coated Drills Using Experimental and Artificial Neural Networks Technique

2020 ◽  
Vol 10 (23) ◽  
pp. 8633
Author(s):  
Muhammad Aamir ◽  
Majid Tolouei-Rad ◽  
Ana Vafadar ◽  
Muhammad Nouman Amjad Raja ◽  
Khaled Giasin
Keyword(s):  
Surface Roughness ◽  
Thrust Force ◽  
Drilling Process ◽  
Hole Quality ◽  
Drilling Performance ◽  
Coated Tools ◽  
Drilling Parameters ◽  
Increase Productivity ◽  
Coated Carbide ◽  
Multiple Holes

Multi-spindle drilling simultaneously produces multiple holes to save time and increase productivity. The assessment of hole quality is important in any drilling process and is influenced by characteristics of the cutting tool, drilling parameters and machine capacity. This study investigates the drilling performance of uncoated carbide, and coated carbide (TiN and TiCN) drills when machining Al2024 aluminium alloy. Thrust force and characteristics of hole quality, such as the presence of burrs and surface roughness, were evaluated. The results show that the uncoated carbide drills performed better than the TiN and TiCN coated tools at low spindle speeds, while TiCN coated drills produced better hole quality at higher spindle speeds. The TiN coated drills gave the highest thrust force and poorest hole quality when compared with the uncoated carbide and TiCN coated carbide drills. Additionally, a multi-layer perceptron neural network model was developed, which could be useful for industries and manufacturing engineers for predicting the surface roughness in multi-hole simultaneous drilling processes.

Study on ultrasonic-assisted drilling of Ti6Al4V using 3-flute drill in the finite element simulation

2019 ◽  
Vol 234 (7) ◽  
pp. 1298-1310 ◽  
Author(s):  
Peng Wang ◽  
Dazhong Wang
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Thrust Force ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Drilling Process ◽  
Wear Depth ◽  
Drill Bit ◽  
Drilling Parameters ◽  
Ultrasonic Assisted

Continuous chip is one of the major problems during drilling Ti6A14V, and chip breaking is dependent on many factors such as drilling parameters, tool geometries and type of drill bits used. This paper attempts to analyze the effect of various drilling parameters such as feed rate, spindle speed on performance characteristics such as chip morphology, thrust force, temperature, and tool wear in conventional drilling and ultrasonic-assisted drilling of Ti6A14V using twist drill bit and 3-flute drill bit in order to optimize the chip breakability of Ti6A14V. The twist and 3-flute drill bit are utilized to establish the finite element models to simulate the drilling process with Lagrangian approach in DEFORM-3D software. The results of the simulations not only reveal obvious varying regular pattern of thrust force, temperature, tool wear depth, chip thickness and damage with the increasing of feed rates, spindle speeds, which confirm the capability and advantage of finite element model of the drilling process, but also provide a more profound knowledge about the drilling mechanism including the effect of 3-flute drill bit in ultrasonic-assisted drilling on chip breakability and tool wear.

Investigation of Forces in Deep Hole Bone Drilling

2018 ◽  
Author(s):  
JuEun Lee ◽  
Serena Chu ◽  
Craig L. Chavez
Keyword(s):  
Thrust Force ◽  
Early Stage ◽  
Chip Morphology ◽  
High Ratio ◽  
Hole Drilling ◽  
Drilling Process ◽  
Drill Bit ◽  
Deep Hole ◽  
Bone Drilling ◽  
Drilling Depth

Deep hole drilling is required to install prosthetic devices in surgical implantation. Compared to the common bone drilling processes, deep hole bone drilling is performed with a larger hole depth (i.e., up to a depth of approximately 35 mm in cochlear implantation) using a high ratio of the length to diameter of the drill bit. For successful outcomes from this process, forces must be controlled adequately to avoid other complications such as drill-bit breakage or thermal necrosis. This study investigates the thrust force and torque generated in bone drilling process of up to 36 mm drilling depth. Drilling tests were performed on bovine cortical bone using 2.5 mm diameter twist drill bit with a spindle speed of 3000 rpm, and feed rates of 0.05, 0.075, and 0.1 mm/rev. Two distinct states in both the thrust force and torque data were observed for all conditions, which are called normal and abnormal states in this study. At an early stage of the drilling process, the force signals showed the traditional trend, reaching a constant value once the tip of the drill bit was fully engaged in bone cutting up to a certain depth. After that, both thrust force and torque kept increasing rapidly until the final drilling depth. This study also observed that the chip morphology varies with increasing drilling depth, showing fragmented chips at the normal state and powdery chips at the abnormal state. Chip clogging and increased frictional force between chips, tool, and hole wall with larger drilling depth may cause the abrupt increase in forces and variation in chip morphology.

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