scholarly journals Comparative Analysis of Cutting Forces, Torques, and Vibration in Drilling of Bovine, Porcine, and Artificial Femur Bone with Considerations for Robot Effector Stiffness

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Oluseyi Adewale Orelaja ◽  
Xingsong Wang ◽  
Donghua Shen ◽  
Dauda Sh. Ibrahim ◽  
Tianzheng Zhao ◽  
...  
Keyword(s):  
Comparative Analysis ◽  
Cutting Forces ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Drilling Process ◽  
Robot Arm ◽  
Drilling Force ◽  
Significant Drop ◽  
Negative Effect ◽  
Conventional Drilling

Bone drilling is known as one of the most sensitive milling processes in biomedical engineering field. Fracture behavior of this cortical bone during drilling has attracted the attention of many researchers; however, there are still impending concerns such as necrosis, tool breakage, and microcracks due to high cutting forces, torques, and high vibration while drilling. This paper presents a comparative analysis of the cutting forces, torques, and vibration resulted on different bone samples (bovine, porcine, and artificial femur) using a 6dof Robot arm effector with considerations of its stiffness effects. Experiments were conducted on two spindle speeds of 1000 and 1500 rpm with a drill bit diameter of 2.5 mm and 6 mm depth of cut. The results obtained from the specimens were processed and analyzed using MATLAB R2015b and Visio 2000 software; these results were then compared with a prior test using manual and conventional drilling methods. The results obtained show that there is a significant drop in the average values of maximum drilling force for all the bone specimens when the spindle speed changes from 1000 rev/min to 1500 rev/min, with a drop from (20.07 to 12.34 N), approximately 23.85% for bovine, (11.25 to 8.14 N) with 16.03% for porcine, and (5.62 to 3.86 N) with 33.99% for artificial femur. The maximum average values of torque also decrease from 41.2 to 24.2 N·mm (bovine), 37.0 to 21.6 N·mm (porcine), and 13.6 to 6.7 N·mm (artificial femur), respectively. At an increase in the spindle speed, the vibration amplitude on all the bone samples also increases considerably. The variation in drilling force, torque, and vibration in our result also confirm that the stiffness of the robot effector joint has negative effect on the bone precision during drilling process.

Evaluation of CFRP Hole Quality in Low Frequency Vibration-Assisted Dry Drilling of CFRP/Ti Stacks

2018 ◽  
Author(s):  
Haojun Yang ◽  
Yan Chen ◽  
Jiuhua Xu
Keyword(s):  
Feed Rate ◽  
Kinematic Model ◽  
Mechanical Damage ◽  
Low Frequency ◽  
Spindle Speed ◽  
Hole Quality ◽  
Drilling Force ◽  
Low Frequency Vibration ◽  
The Impact ◽  
Conventional Drilling

Low frequency vibration assisted drilling (LFVAD) is regarded as one of the most promising process in CFRP/Ti stacks drilling. This work carries the investigation of the difference between conventional drilling and LFVAD based on kinematic model. The experiments are conducted under varied vibration amplitude to a specific feed rate, also under varying spindle speeds, feed rates when the ratio of amplitude to feed rate is fixed. Then the hole quality of CFRP is evaluated based on the analysis of drilling force, chip morphology, chip extraction. The results show that there is rarely no difference between conventional drilling and LFVAD in drilling mechanism when the drilling diameter is over 1 mm. Because the impact effect caused by drill vibration is already weak. It is found that the severe mechanical damage of the CFRP holes surface could be significantly reduced due to the fragmented chips obtained in vibration drilling. The maximum instantaneous feed rate combined with feed rate and amplitude plays a significant role in CFRP hole quality. Lower maximum instantaneous feed rate results in better hole wall quality and less entry delamination. Spindle speed has no visible influence on entry delamination, while higher spindle speed improves the hole surface quality due to the resin coating phenomenon.

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 Machinability of Zirconia Toughened Mica Glass Ceramics for Dental Restorations

2020 ◽  
Vol 24 (1) ◽  
Author(s):  
Sivaranjani Gali ◽  
Suresh Chiru
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Glass Ceramics ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Dental Ceramics ◽  
Edge Chipping ◽  
Dental Restorations

Objective: For a dental material to be machinable for CAD/CAM technology, it must offer convenient machining, under a given set of cutting conditions. Quantitative evaluation of machinability has been assessed in literature through various parameters such as tool wear, penetration rates, surface roughness, cutting force and power. A machinable ceramic will typically demonstrate a higher tool penetration rate with signs of reduced diamond tool wear and edge chipping. The purpose of this in vitro study was to evaluate the feasibility of machining an experimental ceramic, 20 wt.% zirconia reinforced mica glass ceramics (G20Z) for indirect dental restorations and compare the tool penetration rates of G20Z to commercially available dental ceramics, Presintered Zirconia (PSZ) and IPS emax CAD. Material and Methods:  Precursors of base glass (SiO2 -Al2O3 -K2O -MgO-B2O3 -F) were melted at 15000C for 2 h in a platinum crucible and quenched in deionised water. The glass frit was ball milled with 20 wt. % YSZ (G20Z) and subject to two stage heat treatment in a muffle furnace. Specimens of G20Z (12 X 2 mm) were evaluated for their feasibility of machining under varying spindle speed, depth of cut, and feed rates. Influence of depth of cut, spindle speed and feed rate (vc=8000-16000 rpm, d=0.4-0.8 mm, f=0.1- 0.3 mm/tooth) on cutting forces, material response, surface roughness and tool wear were investigated. Tool penetration rates, tool wear and margin chipping were also evaluated and compared with Pre-sintered Zirconia (PSZ)  and e.max CAD in a custom dental milling surveyor at 30,000 rpm with a load of 0.98 N under water lubrication for 6 min. Tool penetration rates were calculated as the ratio of length of cut and milling time with a measuring microscope and scanning electron microscope was used for tool wear and edge chipping. ANOVA and Tukey Kramer tests were used for statistically comparing the means of each group. Results: Spindle speed and feed rate play a significant role in influencing surface roughness, thrust force, cutting forces and tool wear. Penetration rates of G20Z (0.32 ±0.12 mm/min) was significantly greater than PSZ (0.26 ±0.06 mm/min) and IPS e.max CAD (0.21 ±0.05 mm/min). SEM observations reveal tool abrasion and edge chipping regardless of the ceramic type. Conclusion: High spindle speeds delivers low cutting forces with an average surface roughness of 1.61 µm, with abrasive wear of the tool insert and brittle fracture of zirconia mica glass ceramic composites. G20Z with its machinable nature demonstrates greater tool penetration rates than PSZ and IPS e.max CAD. Tool wear and edge chipping is seen in all the investigated ceramics.   Keywords Machinability, Dental Ceramics, Mica Glass-Ceramics, Dental Zirconia, Tool penetration rates.  

scholarly journals Ultrasonic-Assisted Drilling of Cortical and Cancellous Bone in a Comparative Point of View

2021 ◽  
Author(s):  
Sousan Pourgiv ◽  
Nima Jamshidi ◽  
Aminollah Mohammadi ◽  
Alireza Mosavar
Keyword(s):  
Bone Tissue ◽  
Cancellous Bone ◽  
Healing Process ◽  
Drilling Process ◽  
Drilling Force ◽  
Excessive Heat ◽  
Micro Cracks ◽  
Ultrasonic Assisted ◽  
Conventional Drilling

Abstract Background: A potential method in drilling of bone is ultrasonic-assisted drilling. In addition, during the drilling of bone, which is common in clinical surgeries, excessive heat generation and drilling force may lead to damages in bone tissue, and thus to failure of implants and fixation screws or delay in healing process. The aim of this study was to appraise efficiency of ultrasonic-assisted drilling in comparison to conventional drilling.Methods: In addition to investigating drilling force and temperature elevation, their effects on arising osteonecrosis and micro-cracks were explored in ultrasonic-assisted and conventional drilling through histopathologic assessment and microscopic imaging. In this regard, three drilling speeds and two drilling feed-rates were considered as drilling variables in the in-vitro experiments. Moreover, numerical modeling gave an insight into temperature distribution during drilling process in the both methods and compared three different vibration amplitudes. Results: Although temperature elevations were lower in the conventional drilling, the ultrasonic-assisted drilling had lesser drilling forces. Furthermore, the latter method had smaller osteonecrosis regions, and did not have micro-cracks in cortical bone and destructions in structure of cancellous bone.Conclusions: The ultrasonic-assisted drilling, which caused lesser damages to the bone tissue in both cortical and cancellous bone, was more comparatively advantageous.

Study on Drilling Characteristics of Supper Alloy GH3039

2014 ◽  
Vol 800-801 ◽  
pp. 119-123 ◽  
Author(s):  
Xue Hui Wang ◽  
Can Zhao ◽  
Yan Yan Guo ◽  
Ming Jun Feng
Keyword(s):  
Removal Rate ◽  
Aerospace Industry ◽  
Influence Factors ◽  
Spindle Speed ◽  
Major Influence ◽  
Drilling Process ◽  
Single Factor ◽  
Drilling Force ◽  
Serrated Chip ◽  
Speed Up

This paper explores the drilling characteristics of GH3039 supper alloy. The machining of GH3039 is a difficulty which is commonly used in aircraft and engineer components of the aerospace industry. The spindle speed and feed per tooth are the major influence factors which are studied to gain large removal rate and predict the drilling characteristics. So the single factor test is carried out about spindle speed and feed per tooth. The results of the experiment show that the drilling force of GH3039 decreased with the increasing of spindle speed up to 900r/min which is larger than other metal drilling process. The small feed per tooth may obtain small drilling force. So too low spindle speed and large feed per tooth are not adopted in the GH3039 drilling process. The analysis of the chip formation also verifies the above characteristics. At the same time, the serious serrated chip is occurred which is adverse for the drilling. It has significant for other supper alloy real drilling process.

Modeling of Surface Roughness in Drilling of MDF Panels

2015 ◽  
Vol 766-767 ◽  
pp. 831-836 ◽  
Author(s):  
T.N. Valarmathi ◽  
K. Palanikumar ◽  
S. Sekar
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Forces ◽  
Spindle Speed ◽  
Machining Process ◽  
Drilling Process ◽  
Composite Panels ◽  
Wood Composite ◽  
Control Parameters ◽  
Input Control

Medium density fiberboard wood composite panels are preferred for many domestic and industrial applications over the natural wood because of their high-quality properties. The aesthetic appearance of wood composites makes them suitable for interior and exterior construction works. Among various machining process, drilling is the most frequently used machining operation in the furniture industry in assembly of panel products. During drilling process the drill exhibits cutting forces such as thrust force and torque. The surface quality of the drilled holes are mainly affected by the cutting forces developed during drilling process which causes surface roughness, delamination like damages which leads to the rejection of the final product. Hence the reduction of the drilling defects, the control of the cutting forces is very much essential. The drilling parameters play an important role in controlling the cutting forces. The objective of this work is to study the influence of input control parameters such as spindle speed, feed rate and point angle on surface roughness in drilling of MDF panels to obtain the optimal cutting conditions. In the present study the drilling experiments are conducted using Taguchi design of experiments on wood composite panels with high speed steel (HSS) twist drills with different point angles on vertical machining center using at dry condition. Three levels and three factors are considered. Taguchi L27 orthogonal array is used. Response surface methodology is used to develop a mathematical model to predict the influence of input control parameters on cutting forces. Analysis of variance is used to check the adequacy of the model. Surface roughness is increased with an increase of feed rate and drill point angle and decreased with an increase in the spindle speed. It is revealed that high spindle speed with low feed rate and smaller point angle combination gives better results in drilling of wood composite panels.

Prediction of Surface Roughness and Optimization of Cutting Parameters in CNC Turning of Rotational Features

2020 ◽  
Vol 38 (8A) ◽  
pp. 1143-1153
Author(s):  
Yousif K. Shounia ◽  
Tahseen F. Abbas ◽  
Raed R. Shwaish
Keyword(s):  
Surface Roughness ◽  
Linear Regression ◽  
Regression Model ◽  
Linear Regression Model ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Non Linear ◽  
Optimization Of Cutting Parameters

This research presents a model for prediction surface roughness in terms of process parameters in turning aluminum alloy 1200. The geometry to be machined has four rotational features: straight, taper, convex and concave, while a design of experiments was created through the Taguchi L25 orthogonal array experiments in minitab17 three factors with five Levels depth of cut (0.04, 0.06, 0.08, 0.10 and 0.12) mm, spindle speed (1200, 1400, 1600, 1800 and 2000) r.p.m and feed rate (60, 70, 80, 90 and 100) mm/min. A multiple non-linear regression model has been used which is a set of statistical extrapolation processes to estimate the relationships input variables and output which the surface roughness which prediction outside the range of the data. According to the non-linear regression model, the optimum surface roughness can be obtained at 1800 rpm of spindle speed, feed-rate of 80 mm/min and depth of cut 0.04 mm then the best surface roughness comes out to be 0.04 μm at tapper feature at depth of cut 0.01 mm and same spindle speed and feed rate pervious which gives the error of 3.23% at evolution equation.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

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