scholarly journals Characterization of Thrust Force, Temperature, Chip Morphology and Power in Ultrasonic-assisted Drilling of Aluminium 6061

2021 ◽  
Author(s):  
Amin Moghaddas
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Chip Morphology ◽  
High Amplitude ◽  
Spindle Speed ◽  
Drilling Parameters ◽  
Out Of Sample ◽  
Ultrasonic Assisted ◽  
Turning Center ◽  
Chip Size

Abstract In this study, a special resolution V design and Response surface methodology (RSM) were used to characterize the ultrasonic-assisted drilling (UAD) process of Aluminum 6061. This characterization was done through developing mathematical models to study the effect of ultrasonic and drilling parameters including spindle speed, feed rate and amplitude on thrust force, temperature, chip morphology and power. The tests were done using an industrially hardened non-rotating UAD system mounted in a CNC turning center. The analysis of variance (ANOVA) was used to find significant parameters of thrust force, temperature, chip morphology and power. Then, for all responses, the optimum drilling parameters that provide desired solutions for all responses were obtained. This was followed by out-of-sample testing to verify the accuracy of the developed models. The results of this study showed that in UAD of aluminum, the minimum values of thrust force and chip size were obtained at low spindle speed, low feed rate and high amplitude. The results also showed that amplitude was not a significant parameter affecting the tool temperature and cannot be used to analyze the effect of ultrasonic vibrations on generated heat during UAD. Instead, the interaction of amplitude and feed rate was significant and should be considered in the analysis. Finally, minimum consumed power, specially at higher amplitudes, can be obtained using high spindle speed and low feed rate.

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.

Machinability of drilling T700/LT-03A carbon fiber reinforced plastic (CFRP) composite laminates using candle stick drill and multi-facet drill

2015 ◽  
Vol 29 (10n11) ◽  
pp. 1540031 ◽  
Author(s):  
Cheng-Dong Wang ◽  
Kun-Xian Qiu ◽  
Ming Chen ◽  
Xiao-Jiang Cai
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Composite Laminates ◽  
Thrust Force ◽  
Spindle Speed ◽  
Carbon Fiber Reinforced Plastic ◽  
Fiber Reinforced Plastic ◽  
Reinforced Plastic ◽  
Drilling Parameters ◽  
Cfrp Composite

Carbon Fiber Reinforced Plastic (CFRP) composite laminates are widely used in aerospace and aircraft structural components due to their superior properties. However, they are regarded as difficult-to-cut materials because of bad surface quality and low productivity. Drilling is the most common hole making process for CFRP composite laminates and drilling induced delamination damage usually occurs severely at the exit side of drilling holes, which strongly deteriorate holes quality. In this work, the candle stick drill and multi-facet drill are employed to evaluate the machinability of drilling T700/LT-03A CFRP composite laminates in terms of thrust force, delamination, holes diameter and holes surface roughness. S/N ratio is used to characterize the thrust force while an ellipse-shaped delamination model is established to quantitatively analyze the delamination. The best combination of drilling parameters are determined by full consideration of S/N ratios of thrust force and the delamination. The results indicate that candle stick drill will induce the unexpected ellipse-shaped delamination even at its best drilling parameters of spindle speed of 10,000 rpm and feed rate of 0.004 mm/tooth. However, the multi-facet drill cutting at the relative lower feed rate of 0.004 mm/tooth and lower spindle speed of 6000 rpm can effectively prevent the delamination. Comprehensively, holes quality obtained by multi-facet drill is much more superior to those obtained by candle stick drill.

Experimental Study on Drilling Process of CFRP Composite Laminate

2010 ◽  
Vol 638-642 ◽  
pp. 927-932 ◽  
Author(s):  
M.A. Azmir ◽  
Praveena Nair Sivasankaran ◽  
Z. Hamedon
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Optimization Method ◽  
Spindle Speed ◽  
Drilling Process ◽  
Optimal Parameters ◽  
Reinforced Plastics ◽  
Drilling Parameters ◽  
Cfrp Composite ◽  
Split Point

This thesis deals with carbon fiber reinforced plastics (CFRP) composites, an advanced material which is widely used in manufacturing aircrafts because of their unique mechanical and physical properties. The research mainly involved drilling of CFRP. This study is focused on analyzing the thrust force and delamination against drilling parameters namely feed rate, spindle speed and type of tool materials. Also, the optimal parameters were chosen using an optimization method called D optimal. It was observed that the higher the feed rate and spindle speed employed, the higher the thrust force and delamination occur. The split point fibre (SPF) drill gave the lowest values of thrust force and delamination. Based on the optimal parameters, a verification test was conducted and the prediction error was 2.3% and 5.6% for thrust force and delamination respectively. This shows, that the optimal parameters obtained is reliable as it could improve the process considerably. The results of this study could be used as a reference for further research and studies on drilling of CFRP.

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.

Optimization and sensitivity analysis of drilling parameters for sustainable machining of carbon fiber–reinforced polypropylene composites

2018 ◽  
Vol 32 (11) ◽  
pp. 1485-1508 ◽  
Author(s):  
M Mudhukrishnan ◽  
P Hariharan ◽  
K Palanikumar ◽  
B Latha
Keyword(s):  
Sensitivity Analysis ◽  
Carbon Fiber ◽  
Feed Rate ◽  
Thrust Force ◽  
Spindle Speed ◽  
Fiber Reinforced ◽  
Sustainable Machining ◽  
Modeling And Optimization ◽  
Drilling Parameters ◽  
Pp Composites

Machining processes face two major challenges: sustainability and cleaner production. However, the effective utilization of tool and methods of lubrication system in sustainable machining have been dealt in depth in earlier investigations. This work aims to optimize sustainable machining parameters in drilling process for recyclable carbon fiber-reinforced polypropylene (CFR-PP) composites. This work is focused on modeling and optimization of drilling parameters for sustainable machining with respect to thrust force and torque for CFR-PP composites. The response surface method based on D-optimal design of experiments is used for modeling and optimization with variables such as drill spindle speed and drill feed rate as numerical factors, which includes different drill material as the categorical factor. The influences of tool materials on the sustainable machining are also discussed in detail. Further, the sensitivity analysis is applied to compare the relative impact of control parameters (spindle speed, feed rate, and drill materials) on thrust force and torque. The scanning electron microscope images are used for analyzing the morphologies of drilled surfaces.

scholarly journals Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack

2021 ◽  
Vol 5 (7) ◽  
pp. 189
Author(s):  
Muhammad Hafiz Hassan ◽  
Jamaluddin Abdullah ◽  
Gérald Franz ◽  
Chim Yi Shen ◽  
Reza Mahmoodian
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Critical Dimension ◽  
Helix Angle ◽  
Single Shot ◽  
Twist Drill ◽  
Hole Quality ◽  
Drilling Parameters ◽  
Industry Practice ◽  
Maximum Thrust

Drilling two different materials in a layer, or stack-up, is being practiced widely in the aerospace industry to minimize critical dimension mismatch and error in the subsequent assembly process, but the compatibility of the drill to compensate the widely differing properties of composite is still a major challenge to the industry. In this paper, the effect of customized twist drill geometry and drilling parameters are being investigated based on the thrust force signature generated during the drilling of CFRP/Al7075-T6. Based on ANOVA, it is found that the maximum thrust force for both CFRP and Al7075-T6 are highly dependent on the feed rate. Through the analysis of maximum thrust force, supported by hole diameter error, hole surface roughness, and chip formation, it is found that the optimum tool parameters selection includes a helix angle of 30°, primary clearance angle of 6°, point angle of 130°, chisel edge angle of 30°, speed of 2600 rev/min and feed rate of 0.05 mm/rev. The optimum parameters obtained in this study are benchmarked against existing industry practice of the capability to produce higher hole quality and efficiency, which is set at 2600 rev/min for speed and 0.1 mm/rev for feed rate.

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.

Experiments of Drilling Titanium Alloy with Varying Operation Parameters

2017 ◽  
Vol 748 ◽  
pp. 254-258
Author(s):  
Chang Yi Liu ◽  
Bai Shou Zhang ◽  
Suman Shrestha
Keyword(s):  
Titanium Alloy ◽  
Feed Rate ◽  
Thrust Force ◽  
Maximum Amount ◽  
Spindle Speed ◽  
Drilling Process ◽  
Process Variables ◽  
Experimental Cutting ◽  
Operation Parameters ◽  
Titanium Alloy Ti6al4v

Drilling experiments of titanium alloy Ti6Al4V were conducted. Taking the speed and feed as the process variables, a set of experimental cutting forces are obtained and compared. From the experimental results it is concluded that within the experimental extent the thrust force and torque of drilling process rises with the feed rate. The lower spindle speed resulted in the greater amount of thrust. Feed rates have greater influence on the thrust force than the spindle speed. The combination of greater feed rate and lower spindle speed results in the maximum amount of thrust. However, combination of greater feed rate and spindle speed resulted in maximum amount of torque.

Effects of cutting temperature and process optimization in drilling of GFRP composites

2020 ◽  
Vol 55 (2) ◽  
pp. 235-249
Author(s):  
A Tamer Erturk ◽  
Fahri Vatansever ◽  
Eser Yarar ◽  
E Asım Guven ◽  
Tamer Sinmazcelik
Keyword(s):  
Feed Rate ◽  
Cutting Temperature ◽  
Spindle Speed ◽  
Glass Fiber Reinforced ◽  
Drill Bits ◽  
Drilling Parameters ◽  
Tool Coating ◽  
Composite Interface ◽  
Composite Drilling ◽  
Push Out

The present work deals with temperature effects and parametric optimization in the drilling of continuous glass fiber reinforced epoxy composite. Drilling ability was examined operating a drilling system with different drill bits, feed rate, and spindle speed parameters. The investigation was performed by changing the tool and composite interface. Drilling experiments were carried out under the dry condition. Thrust force and drilling temperatures were measured using dynamometer and thermal camera. Peel-up and push-out delamination were evaluated using an image analyzing tool. Results show that the tribo-mechanical behavior of the drilling operation is affected at different levels by tool coating. This behavior is related to the intrinsic friction properties of coating nature. Response surface methodology was used in the evaluation of experiment results. The feed rate of 0.13 mm/rev, spindle speed of 2425 rpm and HSS-TiN drill bit are found as an optimum drilling parameters and drill type.

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