scholarly journals Experimental Investigation On Machining Performance During Orbital Drilling of CFRP

2021 ◽  
Author(s):  
Linghao Kong ◽  
Dong Gao ◽  
Yong Lu ◽  
Pengfei Zhang
Keyword(s):  
Tool Wear ◽  
Thrust Force ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Machining Performance ◽  
Machining Quality ◽  
Orbital Drilling ◽  
Orthogonal Experiments ◽  
Hole Making ◽  
Tool Diameter

Abstract As the most promising CFRP hole making method, orbital drilling is widely concerned. This paper aims to understand the influence of the cutting parameters, tool diameters and ratio between milling and drilling (Rm&d) on thrust force, cutting temperature, tool wear and machining quality in CFRP orbital drilling. The effects of cutting parameters on thrust force and cutting temperature were studied by orthogonal experiments, and experiments were performed to investigate the variations of tool diameters, ratio between drilling and milling on thrust force, cutting temperature, tool wear and machining quality. The experimental results show that the tangential feed rate has no apparent effects on thrust force, but it appreciably impacts on the cutting temperature. The selection of tool diameter and the Rm&d has specific influence on tool wear, machining quality and cutting temperature. The result is helpful for selecting cutting parameters and tool diameters for high quality holes machining in CFRP orbital drilling.

Surface Damages Generated in Hole Making of a Cast Nickel-Based Alloy

2011 ◽  
Vol 697-698 ◽  
pp. 57-60
Author(s):  
C. Xue ◽  
Wu Yi Chen
Keyword(s):  
Tool Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Intrinsic Defect ◽  
Workpiece Material ◽  
Surface Damages ◽  
Hole Making ◽  
Nickel Based Alloy ◽  
Machined Surfaces

The effects of cutting parameters and tool wear on the surface damage generated in hole making of cast GH625 nickel-based alloy were investigated. The machined surfaces were examined by employing a scanning electron microscopy (SEM). The SEM micrographs of the machined surfaces showed that surface damages induced by boring operation comprised surface cavities, smeared material and ridges parallel to feed marks. Surface cavities were associated with the carbide particles contained in workpiece material and the intrinsic defect of cast GH625 alloy. The cutting conditions had little impact on the extent of surface cavities, but they significantly affected the extent of smearing. Severe smearing of workpiece material could occur at higher cutting speed due to the relatively high cutting temperature generated and the relatively rapid tool wear.

Research Status of Subsequent Machining of Laser Cladding Layers

2020 ◽  
Vol 15 ◽  
Author(s):  
Lei Li ◽  
Yujun Cai ◽  
Guohe Li ◽  
Meng Liu
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Laser Cladding ◽  
Wear Surface ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Cladding Layer ◽  
Cladding Layers

Background: As an important method of remanufacturing, laser cladding can be used to obtain the parts with specific shapes by stacking materials layer by layer. The formation mechanism of laser cladding determines the “Staircase effect”, which makes the surface quality can hardly meet the dimensional accuracy of the parts. Therefore, the subsequent machining must be performed to improve the dimensional accuracy and surface quality of cladding parts. Methods: In this paper, chip formation, cutting force, cutting temperature, tool wear, surface quality, and optimization of cutting parameters in the subsequent cutting of laser cladding layer are analyzed. Scholars have expounded and studied these five aspects but the cutting mechanism of laser cladding need further research. Results: The characteristics of cladding layer are similar to that of difficult to machine materials, and the change of parameters has a significant impact on the cutting performance. Conclusion: The research status of subsequent machining of cladding layers is summarized, mainly from the aspects of chip formation, cutting force, cutting temperature, tool wear, surface quality, and cutting parameters optimization. Besides, the existing problems and further developments of subsequent machining of cladding layers are pointed out. The efforts are helpful to promote the development and application of laser cladding remanufacturing technology.

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

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
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.

Cryogenic Machining of Titanium Ti-5553 Alloy

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Yusuf Kaynak ◽  
Armin Gharibi
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Machining Process ◽  
Dry Machining ◽  
Cryogenic Machining ◽  
Machining Performance ◽  
Wide Range ◽  
New Generation

Titanium alloy Ti-5Al-5V-3Cr-0.5Fe (Ti-5553) is a new generation of near-beta titanium alloy that is commonly used in the aerospace industry. Machining is one of the manufacturing methods to produce parts that are made of this near-beta alloy. This study presents the machining performance of new generation near-beta alloys, namely, Ti-5553, by focusing on a high-speed cutting process under cryogenic cooling conditions and dry machining. The machining experiments were conducted under a wide range of cutting speeds, including high speeds that used liquid nitrogen (LN2) and carbon dioxide (CO2) as cryogenic coolants. The experimental data on the cutting temperature, tool wear, force components, chip breakability, dimensional accuracy, and surface integrity characteristics are presented and were analyzed to evaluate the machining process of this alloy and resulting surface characteristics. This study shows that cryogenic machining improved the machining performance of the Ti-5553 alloy by substantially reducing the tool wear, cutting temperature, and dimensional deviation of the machined parts. The cryogenic machining also produced shorter chips as compared to dry machining.

Surface characteristics and machining performance of TiAlN-, TiN- and AlCrN-coated tungsten carbide drills

2018 ◽  
Vol 233 (4) ◽  
pp. 1075-1086 ◽  
Author(s):  
Chaiya Dumkum ◽  
Pakin Jaritngam ◽  
Viboon Tangwarodomnukun
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Thrust Force ◽  
Surface Characteristics ◽  
Average Error ◽  
Force Model ◽  
Machining Performance ◽  
Coating Materials ◽  
Drilling Performance

This article presents a comprehensive analysis of surface characteristics and drilling performance of uncoated and coated tungsten carbide drills. The single- and double-layer coatings of TiN, TiAlN and AlCrN were examined in terms of surface roughness, microhardness and crack resistance. In addition, drilling torque and thrust force were experimentally measured and compared to the developed models based on the drilling mechanics and drill geometries. Tool wear and hole surface roughness were also considered to assess the machining performance of different coated tools. The results revealed that all coated drills can offer better cut surface quality, 28% lower cutting loads and longer tool life than the uncoated drills. Although AlCrN was found to be the hardest coating material among the others, it caused large wear on the cutting edges and poor surface roughness of produced holes. The lowest torque and thrust force were achievable using TiN-coated drill, while the use of TiAlN coating resulted in the lowest surface roughness and smallest tool wear. Furthermore, the drilling torque and thrust force model developed in this study were found to correspond to the experimental measures with the average error of 8.4%. The findings of this work could facilitate the selection of coating materials to advance the machining performance.

scholarly journals Using artificial neural network models for the prediction of thrust force and torque in drilling operation of Al7075

2018 ◽  
Vol 178 ◽  
pp. 01008
Author(s):  
Panagiotis Kyratsis ◽  
Nikolaos Efkolidis ◽  
Daniel Ghiculescu ◽  
Konstantinos Kakoulis
Keyword(s):  
Thrust Force ◽  
Network Models ◽  
Cutting Parameters ◽  
Drilling Process ◽  
Neural Network Models ◽  
Cutting Velocity ◽  
Artificial Neural ◽  
Hidden Layer ◽  
The One ◽  
Tool Diameter

This study investigates the thrust force (Fz) and torque (Mz) in a drilling process of an Al7075 workpiece using solid carbide tools (Kennametal KC7325), depending on the effects of crucial cutting parameters such as cutting velocity, feed rate and tool diameter of 10mm, 12mm and 14mm. Artificial neural networks (ANN) methodology is used in order to acquire mathematical models for both the thrust force (Fz) and torque (Mz) related to the drilling process. The ANN results showed that the best prediction topology of the network for the thrust force was the one with five neurons in the hidden layer, while for the case of Mz the best network topology for the prediction of the experimental values was the one with six neurons in the hidden layer. Based on the results acquired, the ANN models achieved accuracy of 1,96% and 1,95% for both the thrust force and torque measured, while the R coefficient for the prediction model of the thrust force is 0.99976 and 00.99981 for the torque. As a result they can be considered as very accurate and appropriate for their prediction.

Experimental Study on Orbital Drilling Force and Machining Quality of CFRP

2014 ◽  
Vol 1061-1062 ◽  
pp. 542-549
Author(s):  
Xue Mei Chen ◽  
Qing Liang Chen ◽  
Feng Tao He ◽  
Xi Feng Fan
Keyword(s):  
Thrust Force ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Drilling Force ◽  
Drilling Tool ◽  
Orbital Drilling ◽  
Reinforced Plastic ◽  
Predominant Factor

This paper aims to investigate orbital drilling process in carbon-fiber reinforced plastic (CFRP) composites with multi-point orbital drilling tool based on the robot automatic drilling system. One orthogonal experiment has been carried out, and the cutting forces of different parameters were measured online by dynamometer. Furthermore, the cutting force model was established through regression analysis, and the impacts of cutting parameters on thrust force were deeply analyzed. In addition, delamination and tear defects were inspected respectively, and the relationship between thrust force and delamination and tear was discussed. Our results indicate that thrust force increased with the increasing feed rate and axial feed depth, while decreased with the increasing spindle speed. Axial feed depth was found as the predominant factor on thrust force and defects. At last, the cutting parameters was optimized and then thrust force decreased more than 26% with almost none tear and burr around the hole, which indicates a better machine quality.

Tool Wear of Diamond Tools in Ultrasonic Vibration Turning Titanium Alloys

2012 ◽  
Vol 229-231 ◽  
pp. 517-520 ◽  
Author(s):  
Zhi Min Zhou ◽  
Xiao Yan Li ◽  
Yuan Xin Qu ◽  
Jian Na
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Ultrasonic Vibration ◽  
Diamond Tool ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Turning Process ◽  
Diamond Tools ◽  
Tc4 Titanium Alloy ◽  
Superior Mechanical Properties

Titanium alloys, as difficult-to-cut materials, have poor machinability due to their superior mechanical properties, heat resistance and corrosion resistance. High cutting temperature and great cutting force that will greatly accelerate tool wear often occurs in titanium alloys cutting process. In this paper, an ultrasonic vibration turning method was used to lower diamond tool wear during TC4 titanium alloy turning process. Ultrasonic vibration turning tests were carried out with various cutting parameters. Experimental results indicated that there’s a significant reduction of the wear rate of diamond tools by means of ultrasonic vibration in TC4 turning process. For ultrasonic vibration turning, spindle speed, the amplitude and frequency of vibration of the tool are the greatest impact of tool wear, followed by feed rate, then the cutting depth.

Effects of Cutting Parameters on Tool Wear and Thrust Force in Drilling Nickel-Titanium (NiTi) Alloys Using Coated and Uncoated Carbide Tools

2018 ◽  
Vol 791 ◽  
pp. 111-115 ◽  
Author(s):  
Rosmahidayu Rosnan ◽  
Azwan Iskandar Azmi ◽  
Muhamad Nasir Murad
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Thrust Force ◽  
Cutting Parameters ◽  
Nickel Titanium ◽  
Burr Formation ◽  
Machining Processes ◽  
Drilling Parameters ◽  
Mechanical Machining ◽  
Coated Carbide

The difficulties of machining nickel-titanium alloys are due to their high ductility and super-elasticity, strong strain-hardening, and excellent wear resistance. These characteristics lead to poor chip breakability, high cutting forces, rapid and aggressive tool-wear, as well as excessive burr formation during mechanical machining processes. The present study addresses these issues by evaluating the effects of drilling parameters and drill bit coatings on the growth of tool wear and development of the drilling thrust force. The findings from this research indicate that the TiAlN coated carbide drill was found to significantly improve the wear resistance of the cutting tool. Likewise, the results of thrust force development are consistent with the trends of tool wear growth for all of the tested carbide drills.

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