scholarly journals Recent advances in twist drill design for composite machining: A critical review

2016 ◽  
Vol 231 (14) ◽  
pp. 2527-2542 ◽  
Author(s):  
Sikiru Oluwarotimi Ismail ◽  
Hom Nath Dhakal ◽  
Eric Dimla ◽  
Ivan Popov
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
Critical Review ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Clear Understanding ◽  
Twist Drill ◽  
Twist Drills ◽  
Composite Drilling ◽  
Drill Design

In the field of composite technology, inefficient and poor designs of twist drills contribute immensely to the challenges facing drilling of composite materials. An attempt to report some of the drill design methods and their inherent challenges confronting composite machining necessitates the writing of this article. A critical review has been conducted to offer a clear understanding of the current advances in the field of mechanical drilling of composite materials, focusing on geometry, material and parametric tool designs. The inter-dependable effects of thrust force, cutting speed, feed rate, cutting force and torque on drill design are similarly reviewed. This article also reveals other associated issues facing composite drilling including delamination, surface roughness, rapid tool wear and drill breakage. Well-designed drill geometry and good knowledge of drilling parameters afford the producers of polycrystalline diamond, carbide and high-speed steel tooling materials better opportunity of developing a drill that will minimise delamination of the reinforced composites and tool wear and produce a high-quality surface. Twist drill manufacturers and users will benefit from this article as they seek to have well-designed and improved drills.

Machinability of Fiber-Reinforced Thermoplastics in Drilling

1993 ◽  
Vol 115 (1) ◽  
pp. 146-149 ◽  
Author(s):  
H. Hocheng ◽  
H. Y. Puw
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Fiber Reinforced ◽  
Heat Accumulation ◽  
Edge Quality ◽  
Carbon Fiber Reinforced

Polymer-based composite materials are used in a variety of industry. Recently, thermoplastic polymer suitable for the resinous matrix in carbon fiber-reinforced composites has been introduced for lower material and processing costs, improved damage tolerance and higher moisture resistance. The successful use of this material requires sophisticated production technology, however little reference of machining of thermoplastics composites can be found. The existing published results are almost exclusively for epoxy-based composite materials showing difficulty in avoiding poor finish, serious tool wear and delamination at hole entrance and exit due to the brittle material response to machining. Thermoplastics-based composite materials possesses better machinability. The current work reveals the machinability of an example of carbon fiber-reinforced ABS (Acrylonitrile Butadiene Styrene) in drilling compared to representative metals and thermoset-based composites. The observation of chips reveals that considerable plastic deformation is involved. Compared to the chip formation of thermoset plastics, it contributes to the improved edge quality in drilling. The edge quality is generally fine except in the case of concentrated heat accumulation at tool lips, which is generated by high cutting speed and low feed rate. Plastics tend to be extruded out of the edge rather than neatly cut. The average surface roughness along hole walls in commonly below one micron for all sets of cutting conditions in the experiment, values between 0.3 and 0.6 microns are typical. The high speed steel drill presents only minor tool wear during the tests. Based on these results, one concludes that the carbon fiber-reinforced ABS demonstrates good machinability in drilling.

SEM Observations on Wear Mechanism of TiN–Coated HSS Twist Drills When Drilling Mild Steel

2012 ◽  
Author(s):  
R. J. Talib ◽  
S. Saad ◽  
M. R. M. Toff ◽  
A. H. Hashim
Keyword(s):  
Mild Steel ◽  
Wear Mechanism ◽  
Performance Test ◽  
Steel Plate ◽  
High Speed Steel ◽  
Depth Of Cut ◽  
Twist Drill ◽  
Drilling Performance ◽  
Thermal Wear ◽  
Twist Drills

Dalam kajian ini, haus mekanikal Keluli Laju Tinggi (KLT) telah dikaji dengan menjalankan ujian prestasi gerudi ke atas bahan kerja diperbuat daripada keluli lembut. Salutan TiN ke atas HSS twist drills diperolehi dengan menggunakan kaedah bertindak balas frekuensi radio pemercitan magnetron yang mana dibangunkan secara dalaman. Ujian prestasi gerudi dijalankan pada kelajuan pusingan 1,600 psm, kadar suapan 20 mm/minit dengan kedalaman penggerudian 25 mm. Perubahan morfologi permukaan haus diperhatikan dengan menggunakan kaedah Kemikroskopan Imbasan Elektron (KEI). Keputusan morfologi menunjukkan mekanisme rekatan dan haba beroperasi semasa proses penggerudian. Kertas kerja ini juga akan membincangkan secara mendalam proses penjanaan mekanisme haus rekatan dan haba semasa penggerudian gerudi piuhan ke atas plat keluli lembut. Keputusan ujian prestasi gerudi menunjukkan salutan TiN terendap ke atas KLT gerudi piuhan telah meningkatkan umur gerudi melebihi dua kali ganda jika dibandingkan dengan gerudi yang tidak bersalut. Kata kunci: Gerudi KLT, KEI, mekanisme haus, rekatan, haba In this study, High Speed Steel (HSS) twist drills were investigated for mechanical wear by performing drilling test on the work piece of mild steel plate. TiN coatings onto the HSS twist drills were achieved by employing reactive radio frequency (r.f) magnetron sputtering technique, which was developed in–house. The drilling performance tests were set at a rotation speed of 1,600 rpm, feed rate of 20 mm/min, and depth of cut of 25 mm. The morphological changes of the wear surface were observed using Scanning Electron Microscopy (SEM). Results of morphological examination showed that the failure mechanisms in operation during drilling were found to be adhesive and thermal wear mechanism. This paper will also discuss explicitly the processes of adhesive and thermal wear mechanism generated during drilling of twist drill on mild steel plate. Results of drilling performance test showed that the TiN coating deposited on the HSS twist drill had improved drill life by more than 2 times as compared with uncoated drill. Key words: HSS drill, SEM, wear mechanism, adhesive, thermal

Feasibility Study of the Effectiveness of Cryogenically Treated Ceramic Inserts for Pocket Milling Maneuvers

2009 ◽  
Author(s):  
Justin L. Milner ◽  
Jeffrey A. Beers ◽  
John T. Roth
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Feasibility Study ◽  
High Speed ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Initial Study ◽  
Machining Processes ◽  
Cutting Speeds

Machining is a popular and versatile manufacturing process that is widely used in today’s industry when producing metallic parts; however, limited tool life can make this an expensive and time consuming fabrication technique. Consequently, methods that decrease the rate of tool wear and, thus, increase tool longevity are a vital component when improving the efficiency of machining processes. To this end, cryogenically treating cutting tools (especially high-speed steel tooling) is becoming more commonplace since research has shown that the treated tooling exhibits significantly higher wear resistance. At this point, however, the effect of cryogenic treatments on ceramic tooling has not been established. Considering this, the research herein presents a feasibility study on the effectiveness of using cryogenic treatments to enhance the wear resistance of WG-300 whisker-reinforced ceramic cutting inserts. To begin, the effect of the cryogenic treatment on the insert’s hardness is examined. Subsequently, tool wear tests are conducted at various cutting speeds. Through this study, it is shown that cryogenically treating the ceramic inserts decreases the rate of tool wear at each of the cutting speeds that were tested. However, the degree of wear resistance introduced by cryogenically treating the inserts proved to be highly dependent on the cutting speed, with slower speeds exhibiting greater improvements. Thus, based on this initial study, the cryogenic treatment of ceramic tooling appears to produce beneficial results, potentially increasing the overall efficiency of machining processes.

New Experiments on the Temperature Distribution in Drilling

1984 ◽  
Vol 106 (3) ◽  
pp. 242-247 ◽  
Author(s):  
A. Thangaraj ◽  
P. K. Wright ◽  
M. Nissle
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Flow ◽  
High Speed Steel ◽  
Twist Drill ◽  
Temperature Distributions ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Twist Drills

Using metallographic and microhardness techniques, temperature distributions have been determined in twist drills. The methods rely on the fact that certain high speed steel materials exhibit microstructural changes when subjected to temperatures greater than 600°C. Quick-stop specimens have also been obtained to study the metal flow patterns over the drill flutes. These results have been used to comment on the different wear mechanisms that affect the performance of a twist drill. Preliminary results show that bulk plastic flow occurs near the margin of the drill where the temperatures are in the vicinity of 900°C when machining AISI 1045 steel at 40 m/min.

EXPERIMENTAL INVESTIGATION OF QUALITY METRICS FORMATION PROCESS DURING PLASTIC MILLING

2016 ◽  
Vol 2016 (3) ◽  
pp. 129-136 ◽  
Author(s):  
Павел Черданцев ◽  
Pavel Cherdantsev ◽  
Андрей Марков ◽  
Andrey Markov ◽  
Софья Катаева ◽  
...  
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
Cutting Speed ◽  
Experimental Investigations ◽  
Geometrical Parameters ◽  
Original Design ◽  
Transverse Fiber ◽  
Fiber Winding ◽  
Estimate Of Parameter ◽  
Cutting Modes

Composite materials are widely used in mechanical engineering, but at edge cutting machining, in particular, during milling these materials a number of peculiarities arise which must be taken into account at the definition of cutting modes and design-geometrical parameters of cutters. Besides, new composite materials machining does not allow using effectively the recommendations developed earlier. In such a way, to solve such a problem it is necessary to carry out experimental investigations on the analysis of the influence of milling mode characteristics and design-geometrical of a tool upon values of roughness of a surface processed and tool wear. As a cutter for investigations there were taken hardmetal endmilling cutters of TC-8 (tungstencobalt) type, the experimental samples – pipes made of composite material with oblique longi-tudinal-transverse fiber winding (OLTFW). As varied parameters were adopted cutting modes: cutting speed V, m/min, feed S, mm/tooth and milling depth t, mm. During the experiments were controlled the following parameters: tool wear Δ, mkm, roughness of the surface Ra, mkm and a depth of a faulty layer h, mkm. To carry out the experiments there was offered an original design of an assembly milling cutter which allows defining in an experimental way optimum geo-metrical parameters of a tools to achieve output milling parameters specified. On the basis of experiments data there are obtained dependences allowing the estimate of parameter modes influence upon the period of cutter duration at the same time a temperature is affected mostly by a milling depth and a feed on a tooth affects the wear of an end flank.

On-Line Monitoring of Drill Wear Using Air-Coupled Audio Microphone when Drilling Composite Materials

2014 ◽  
Vol 590 ◽  
pp. 645-650 ◽  
Author(s):  
Eshetu D. Eneyew ◽  
Mamidala Ramulu
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Flank Wear ◽  
High Speed Steel ◽  
High Rate ◽  
Drilling Process ◽  
Monitoring Method ◽  
On Line

The condition of the cutting tool when drilling composite materials is the controlling factor for the surface integrity of hole produced. The high rate of tool wear when drilling composite materials makes finding a way to monitor the condition of the cutting tool without interrupting the drilling process a great necessity. Inspecting the condition of the drill between or during the drilling process is not practical or economical. In an attempt to tackle this problem, a new approach of on-line tool wear monitoring method using an air-coupled audio microphone is proposed. An experimental investigation was conducted on multi-directional carbon fiber reinforced plastic (CFRP) composite material using a high speed steel (HSS) drill. The result shows that, the amplitude of the acoustic signal from the microphone decreases when the amount of flank wear increases and the amplitude of thrust force and torque increases with the increase of the flank wear. This result demonstrates that the proposed approach can be used as an effective and economical tool for on-line monitoring of cutting tool condition.

Effect of Peripheral Drilling Moment on Critical Thrust Force Using Twist Drill in Drilling Composite Materials

2011 ◽  
Vol 66-68 ◽  
pp. 528-533
Author(s):  
Chung Chen Tsao
Keyword(s):  
Composite Materials ◽  
Thrust Force ◽  
Construction Materials ◽  
Cutting Speed ◽  
Practical Experience ◽  
Twist Drill ◽  
Linear Elastic ◽  
Superior Mechanical Properties ◽  
Elastic Fracture ◽  
Critical Thrust Force

Composites have become valuable construction materials in the aerospace, defense, automobile, and civil industries due to their superior mechanical properties. However, there are significant differences between the machining of metals and alloys and that of composites, because composites are anisotropic and inhomogeneous. Drilling with a conventional twist drill is characterized by a relatively large thrust force due to a negative rake and negligibly small cutting speed at the chisel edge. Such a large thrust force causes defects and damages the composites, leading to poor hole quality, and reduced in-service life under fatigue loads. Although significant efforts have been made to realize the thrust force of twist drill, there are few papers reporting the effect of peripheral drilling moment (torque) on delamination in drilling composite materials. In this paper, an attempt is made to develop the critical thrust of the twist drill with peripheral drilling moment using linear elastic fracture mechanics (LEFM) and energy conservation. The theoretical results agree well with the practical experience in industries.

Optimization of Parameter for HSS Tool Wear by Using Taguchi Method and Finite Element Method

2013 ◽  
Vol 315 ◽  
pp. 151-155
Author(s):  
M.R. Ibrahim ◽  
A.R. Abd. Kadir ◽  
M.S. Omar ◽  
S. Sulaiman ◽  
M.H. Osman
Keyword(s):  
Tool Wear ◽  
Taguchi Method ◽  
Surface Treatment ◽  
High Speed ◽  
Flank Wear ◽  
Simulation Analysis ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Coated Surface

This paper presents the combination between the simulation analysis of FEM (DFORM 3D) and Taguchi method approach. The Taguchi method was used to find the optimize parameter design contribute to Flank wear. The parameters were evaluated are coated surface treatment, cutting speed and feed rate. The Usuis model carried out to measure the flank wear size. Furthermore, ANOVA analysis was used out to identify the influence factors contribute to tool wear in the signal to noise ratio. The experiments were conducted on AL6061 by using High Speed Steel Tool (HSS) in face milling cutting. It shown that, the coated surface treatment is the most significant parameter which can reduce the tool wear value.

Experimental Analysis of Wear Mechanism and Tool Life in Dry Drilling of Al2024

2012 ◽  
Vol 566 ◽  
pp. 217-221 ◽  
Author(s):  
Ali Davoudinejad ◽  
Sina Alizadeh Ashrafi ◽  
Raja Ishak Raja Hamzah ◽  
Abdolkarim Niazi
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dry Machining ◽  
Hole Quality ◽  
High Cutting Speed

Aluminum alloy is widely used in industry and various researches has been done on machiability of this material mainly due to its low weight and other superior properties. Dry machining is still interesting topic to reduce the cost of manufacturing and environmental contaminations. In present study dry machining of Al 2024 investigated on tool life, tool wear mechanisms, hole quality, thrust force and torque. Different types of high speed steel (HSS) tools utilized at constant feed rate of 0.04 mm/rev and cutting speeds within the range of 28 and 94 m/min. Experimental results revealed that HSCo drills, performed better than HSS drills in terms of tool life and hole quality. The main wear mechanisms which analyzed by scanning electron microscope found abrasive and adhesion wear on flank face, besides, BUE observed at chisel and cutting edges. However tool wear and BUE formation found more significant at high cutting speed. In terms of thrust force, two facet HSCo tools, recorded higher thrust force than four facet HSS drills.

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