Numerical and experimental investigation of the hole saw tool geometry effects on drilling of random chopped fiber composites

Drilling is the most widely used machining process in manufacturing holes in many industrial applications. Optimizing the drilling process is a key to improve the hole quality. Therefore, numerical modeling is an effective method that gives an idea about the cutting process to optimize the drilling parameters. This paper emphasizes the sensitivity of the thrust force, the torque and the machining-induced damage to the hole saw tool geometry using a 3D Finite Element (FE) model developed using ABAQUS/Explicit. A Johnson cook model associated with a ductile damage law is used to predict the failure mechanism of a random chopped glass fiber reinforced polyester. It is found that the thrust force, the torque and the damage around the hole obtained from the FE model are in good agreement with the experimental data. Differences of about 2% for the thrust force, 2.4% for the torque and 3% for the damage around the hole are observed. The results of the numerical model also indicated that the thrust force as well as the drilled workpiece quality are improved by choosing the suitable rake angle. A decrease of about 61% in the thrust force is observed when varying the rake angle from 0° to 20°. However, the latter has an insignificant effect on the thrust force. Furthermore, it can be concluded that this parameter highly influences the material removal process.

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

Metals ◽

10.3390/met11060854 ◽

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.

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

Mathematical Problems in Engineering ◽

10.1155/2015/952049 ◽

2015 ◽

Vol 2015 ◽

pp. 1-11 ◽

Cited By ~ 2

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.

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Five-Axis Constrained and Optimal Orientation Planning

19th Design Automation Conference: Volume 1 — Mechanical System Dynamics; Concurrent and Robust Design; Design for Assembly and Manufacture; Genetic Algorithms in Design and Structural Optimization ◽

10.1115/detc1993-0335 ◽

1993 ◽

Author(s):

Khorssand Haghpassand

Keyword(s):

Optimization Problem ◽

Machining Process ◽

Surface Finishing ◽

Tool Geometry ◽

Drilling Process ◽

Workpiece Surface ◽

Optimal Orientation ◽

Manufacturing Applications ◽

Finishing Processes ◽

Five Axis

Abstract The five-axis constrained and optimal orientation planning is formulated as a design optimization problem that incorporates the process machine’s kinematic constraints with the workpiece and tool geometry, to obtain a constrained setup orientation which exploits the maximum capabilities of existing machines. This work will introduce this problem, and will obtain the setup orientation for two different types of rotation structures, i.e., tool rotation and table rotation in O(N) time. Further, the obtained constrained setup orientation, will be augmented to incorporate the workpiece surface magnitude, along with different machine rotation structures, to obtain an optimal setup orientation for different machine rotation structures. The drilling process is also introduced and formulated as additional constraints to the optimization problem. The primary application of the introduced algorithms, is the machining process, where, they can efficiently reduce the number of tool motions and surface finishing processes. However, the solution is very suitable for many manufacturing applications, such as inspection, assembly, robotics, painting, welding, aerospace, electronic surface mount technology, and etc.

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Fuzzy Logic in Hole Drilling of Composites

4th Flexible Assembly Conference ◽

10.1115/detc1994-0363 ◽

1994 ◽

Author(s):

Aditya Thadani ◽

Athamaram H. Soni

Keyword(s):

Fuzzy Logic ◽

Fuzzy Logic Controller ◽

Thrust Force ◽

Cutting Speed ◽

Research Data ◽

Theoretical Research ◽

Hole Drilling ◽

Tool Geometry ◽

Drilling Process ◽

And Control

Abstract Experimental and theoretical research data was utilized in building a Fuzzy Logic Controller model applied to simulate the drilling process of composite materials. The objective is to have a better understanding and control of delamination of composites during the drilling process and at the same time to improve the hole finish by controlling fraying and splintering. By controlling the main issues in the drilling process such as feed rate, cutting speed, thrust force, and torque generated in addition to the tool geometry, it is possible to optimize the drilling process avoiding the conventionally encountered problems.

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An experimental study on the effect of tool geometry on tool wear and surface roughness in hard turning

Advances in Mechanical Engineering ◽

10.1177/1687814020959885 ◽

2020 ◽

Vol 12 (9) ◽

pp. 168781402095988

Author(s):

Pham Minh Duc ◽

Le Hieu Giang ◽

Mai Duc Dai ◽

Do Tien Sy

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Inclination Angle ◽

Hard Turning ◽

Rake Angle ◽

Machining Process ◽

Tool Geometry ◽

Standard Tool ◽

Inclination Angles ◽

Mixed Ceramic

The main purpose of this study is to investigate the influence of tool geometry (cutting edge angle, rake angle, and inclination angle) and to optimize tool wear and surface roughness in hard turning of AISI 1055 (52HRC) hardened steel by using TiN coated mixed ceramic inserts. The results show that the inclination angle is the major factor affecting the tool wear and the surface roughness in hard turning. With the increase in negative rake and inclination angles, the tool wear decreases, and the surface roughness increases. However, the surface roughness will decrease when the inclination angle increases to overpass a certain limit. This is a new and significant point in the research of the hard turning process. From this result, the large negative inclination angle (λ = −10°) should be applied to reduce the surface roughness and the tool wear simultaneously. With the optimal cutting tool angles in the research, the hard machining process is improved remarkably with decreases of surface roughness and tool wear 8.3% and 41.3%, respectively in comparison with the standard tool angles. And the proposed tool-post design approach brings an effective method to change the tool insert angles using standard tool-holders to improve hard or other difficult-to-cut materials turning quality.

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Experimental Investigation and Numerical Prediction of the Effects of Cutting Tool Geometry During Turning of AISI 316L Steel

Periodica Polytechnica Mechanical Engineering ◽

10.3311/ppme.16844 ◽

2021 ◽

Vol 65 (4) ◽

pp. 293-301

Author(s):

Amor Benmeddour

Keyword(s):

Temperature Distribution ◽

Residual Stresses ◽

Cutting Force ◽

Rake Angle ◽

Tool Geometry ◽

Model Parameters ◽

Fe Model ◽

Aisi 316L ◽

Arbitrary Lagrangian Eulerian ◽

The Impact

In this work, a numerical and an experimental study aimed to gain a better understanding of the impact of tool geometry such as (rake angle and cutting edge radius) on the temperature distribution and residual stresses in machining surface of AISI 316L stainless steel have been presented. To evaluate the experimental results, various experimental equipment was used, such as a conventional lathe to carry out the machining operations, the cutting force was measured using a Kistler dynamometer and X-ray diffraction technique was employed for determination of the residual stresses distribution on the machined surfaces. In addition, A thermo-mechanically coupled finite element (FE) analysis for cutting process is developed through ABAQUS code to predict the temperature distribution and residual stresses using an Arbitrary Lagrangian-Eulerian (ALE) approach. An inverse identification method has been used to determine the adequate Johnson-Cook (JC) material model parameters to obtain a good correlation between the cutting force measurements and numerical one. The FE model was then validated by comparison of the numerical results of residual stresses with experimental measurements for different tool geometries, which revealed a reasonable agreement.

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Optimasi Multirespon Gaya Tekan Dan Momen Torsi Pada Penggurdian Material Komposit Glass Fiber Reinforce Polymer (Gfrp) yang Ditumpuk Dengan Material Stainless Steel (SS) Menggunakan Metode Algoritma Genetika

Manutech : Jurnal Teknologi Manufaktur ◽

10.33504/manutech.v9i01.10 ◽

2019 ◽

Vol 9 (01) ◽

pp. 1-5

Author(s):

Angga Sateria

Keyword(s):

Stainless Steel ◽

Glass Fiber ◽

Process Parameters ◽

Feed Rate ◽

Thrust Force ◽

Spindle Speed ◽

Quality Characteristic ◽

Drilling Process ◽

Glass Fiber Reinforced ◽

Different Levels

Glass fiber reinforced polymer (GFRP)-stainless steel stacks used in the aircraft structural components. The assembly process of this components requires mechanical joining using bolt and nut. The drilling process is commonly used for producing hole to position the bolt correctly. Thrust force and torque are responses that used to evaluate the performance of drilling process. The quality characteristic of these responses are “smaller-is-better.” The aim of this experiment is to identify the combination of process parameters for achieving required multiple performance characteristics in drilling process of GFRP-stainless steel stacks materials. The three important process parameters, i.e., point angle, spindle speed, and feed rate were used as input parameters. Point angle was set at two different levels, whilethe other two were set at three different levels. Hence, a 2 x 3 x 3 full factorial was used as designexperiments. The experiments were replicated two times. The optimization was conducted by using genetic algorithm method. The minimum thrust force and torque could be obtained by using point angle, spindle speed and feed rate of 118o, 2383 rpm, 62 mm/min respectively.

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Experimental Study and Investigation of Thrust Force and Delamination Damage of Drilled Ramie Woven Reinforced Composites

International Journal of Automotive and Mechanical Engineering ◽

10.15282/ijame.17.1.2020.11.0566 ◽

2020 ◽

Vol 17 (1) ◽

pp. 7618-7628

Author(s):

S. Chandrabakty ◽

I. Renreng ◽

Z. Djafar ◽

H. Arsyad

Keyword(s):

Thrust Force ◽

Unsaturated Polyester ◽

Machining Process ◽

Drilling Process ◽

Machining Parameters ◽

Reinforced Composite ◽

Polyester Matrix ◽

Ramie Yarn ◽

Reinforced Composite Material ◽

Delamination Damage

One of the machining failures in composite materials is delamination damage. In this paper, machining parameters and delamination damage caused by the drilling process on ramie woven reinforced composite material with an unsaturated polyester matrix were investigated. The ramie woven used is ramie yarn type 12S/3. The machining process used 1.5 kW Pillar drills, where variations in the diameter of the "brad & spur" drill are 4 mm, 6 mm, 8 mm, and 10 mm, respectively. In this work, focuses on the influence of machining parameters like feeds rate and spindle speed. Holes quality was analyzed in terms of thrust force and delamination failure. From the results of this study, the thrust force value obtained at the time of drilling is very closely related to the delamination damage that happens. Delamination damage occurs on both sides of the holes drill.

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Analysis of Thrust Force and Torque in Drilling Process of Particle Board

Materials Science Forum ◽

10.4028/www.scientific.net/msf.818.233 ◽

2015 ◽

Vol 818 ◽

pp. 233-238

Author(s):

Krzysztof Szwajka

Keyword(s):

Mathematical Models ◽

Cutting Forces ◽

Thrust Force ◽

Surface Characteristics ◽

Cutting Parameters ◽

Machining Process ◽

Drilling Process ◽

Machining Parameters ◽

Particle Board ◽

Wood Based Composite

Particleboard is a wood based composite extensively used in wood working. Drilling is the most commonly used machining process in furniture industries. The surface characteristics and the damage free drilling are significantly influenced by the machining parameters. The thrust force developed during drilling play a major role in gaining the surface quality and minimizing the delamination tendency. In this study trials were made eighteen durability tools for different values of the parameters analyzed cut. Based on the results obtained from the study, the effect of cutting parameters selected signals of axial force and torque cutting. Proposed mathematical models using ANOVA, allowing to estimate the cutting forces.

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