scholarly journals Evaluation of machinability of alloy ductile iron in term of thrust drilling force

2020 ◽  
Vol 3 (1) ◽  
pp. 91-97
Author(s):  
Hamed Tanabi
Keyword(s):  
Regression Model ◽  
Alloy Steel ◽  
Ductile Iron ◽  
Feed Rate ◽  
Thrust Force ◽  
Taguchi Approach ◽  
Drilling Force ◽  
Drilling Parameters ◽  
Drilling Conditions ◽  
Thrust Forces

The main aim of this work is the assessment of the machinability of alloyed ductile iron before the austempering process. 16MnCr5 alloy steel and alloyed ductile specimens were subjected to drilling tests. The effect of drilling parameters on cutting force was investigated based on the Taguchi approach. Based on the results, a regression model was established to predict thrust force at various drilling conditions. The predicted thrust forces ratio was then used to evaluate the machinability of alloyed ductile respect to the 16MnCr5 alloy steel. The results showed that at lower feed rate, the normal drilling force is very close for both materials, such that the estimated machinability rating is 86%.

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.

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.

Assessment of Hole Quality and Thrust Force when Drilling CFRP/Al Stack Using Carbide Tools

2012 ◽  
Vol 234 ◽  
pp. 28-33 ◽  
Author(s):  
Sina Alizadeh Ashrafi ◽  
Safian Sharif ◽  
Yahya Mohd Yazid ◽  
Ali Davoudinejad
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Composite Plates ◽  
Machining Performance ◽  
Coated Tools ◽  
Reinforced Plastic ◽  
Metal Chips ◽  
Drilling Conditions

Drilling composite materials is challenging due to the anisotropic and non-homogenous structure of composites. In fabrication works, metals are joined to composites to form a hybrid strengthened structures, and this posed a great problem during drilling, due to the dissimilar drilling conditions for each material and also sharp metal chips effect on the quality of hole on composite plates. This paper evaluates the experimental results on the machining performance of coated and uncoated 4 facet carbide drills when dry drilling stack of carbon fiber reinforced plastic (CFRP) and aluminum. Drilling trials were carried out on CFRP/Al2024/CFRP stack at constant cutting speed of 37 m/min with three feed rates within 0.03-0.25 mm/rev. Results revealed that 4 facet coated drills performed better than uncoated drills in terms of delamination. It was found that hole entry delamination increases with increasing feed rate, however uncut fibers which were dominant at low feeds on hole exit, disappears with increasing feed rate. It was also found that thrust force for coated tools were quite higher than uncoated tools.

scholarly journals Optimization of Drilling Parameters on Alkaline Treated Jute fiber Sandwich Material

2019 ◽  
Vol 8 (3) ◽  
pp. 2454-2459 ◽  
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Sandwich Structures ◽  
Fitness Function ◽  
Entry And Exit ◽  
Drilling Performance ◽  
Drilling Parameters ◽  
Drill Diameter ◽  
Coated Carbide ◽  
Different Levels

The present work efforts to determine CNC drilling performance and optimization of drilling parameters during drilling of treated JFRPPU-foam sandwich structures. In this drilling operation the ensuing process performance structures viz thrust, torque and delamination factor for entry and exit hole have been recognized. The effort has been made to regulate the optimal drilling parameters set. Taguchi method employed for design of experiment. The effects of parameters process such as composite geometry type, feed rate, drill speed, and drill size varied each at three different levels. In this experimentation sandwich structures L27 orthogonal array is used. A nonlinear regression model is measured and formulates the function based on the drilling parameters and fitness function. The result shows the minimization thrust force, delamination of hole drill diameter and feed rate more effect than the speed. TAN coated carbide twist drilled hole gives the result more percentage to reduce the hole wall delamination.

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.

scholarly journals Evaluation of Factors Affecting Delamination, Tensile Strength, Thrust Force and Surface Roughness in Drilling of GFRP

2021 ◽  
Author(s):  
Erol KILICKAP ◽  
Yahya Hışman Celik ◽  
Burak Yenigun
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Gfrp Composites ◽  
Glass Fiber Reinforced Plastic ◽  
Delamination Factor ◽  
Drilling Parameters

Abstract The drilling operation of glass fiber reinforced plastic (GFRP) composites has gained importance because they are used as structural components in many industries such as aerospace and aviation. In the drilling of GFRP composites, some problems such as deformation and fiber breakage occur. Thrust force, delamination, surface quality and cutting temperature are affected by drilling parameters and woven types in the drilling of GFRP composites. At the same time, delamination also affects tensile strength. In this study, the effects of drilling parameters and woven types of GFRP composites on thrust force, surface roughness, delamination factor, and cutting temperature were examined in the drilling of GFRP composites produced in unidirectional (UD), ± 45º and 0°/90º woven types. The effects of drilling parameters and the delamination factor on the tensile strength of the drilled specimen were also investigated. The result of this study indicated that thrust force, delamination factor, and surface roughness increased with increasing cutting speed and feed rate. An increase in feed rate decreased the cutting temperature while an increase in cutting speed increased the cutting temperature. Also, it was found that the delamination had a critical influence on the tensile strength of the GFRP composites.

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.

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.

Effect of Drilling Force on Delamination of Abaca/Kenaf/Carbon Fiber Reinforced Hybrid Composite

2019 ◽  
Vol 12 (1) ◽  
pp. 99-105 ◽  
Author(s):  
M. Venkatasudhahar ◽  
R. Velu
Keyword(s):  
Composite Materials ◽  
Feed Rate ◽  
Hybrid Composite ◽  
Natural Fiber ◽  
Thrust Force ◽  
Fiber Reinforced ◽  
Drilling Force ◽  
Fiber Reinforced Materials ◽  
Drill Diameter ◽  
Tool Diameter

Background: Natural fiber reinforced materials with polymer matrix finds many applications in industries due to its excellent property. Fiber laminate composite materials have been researched around the globe and were tested to determine its beneficial properties for specific purposes. These composite materials have improved to withstand external loads. However, drilling of composite has remained a difficult task because of its anisotropic material properties. Methods: In this study abaca and kenaf woven mat with the carbon woven mat are laminated using epoxy resin (HY 951) and hardener (LY556) as matrix element while preparing the hybrid composite materials. The drilling operations are carried out using automatic feed computer controlled vertical axis drilling machine. Results: It is found that the drilling force, delamination peel up and push out for the composite material depended on feed rates, drill bit diameters and speeds respectively. The optimal input parameters are obtained using Taguchi L27 orthogonal array, Response Surface Methodology (RSM) and Analysis Of Variance (ANOVA) methods. It is observed that lower feed, smaller drill diameter and moderate speed provided high quality drilled hole. The drilled-hole quality, drilling damages are observed by using profile projector. Conclusion: The following conclusion can be drawn from the present investigation on drilling of reinforced composite materials drilled in different conditions. Feed rate is the important factor compared to the feed and the tool diameter. When feed rate is increased, thrust force also increases. However, thrust force decreases when the cutting speed increases. Feed influenced the thrust force instead of speed and torque during drilling. The drilling induced damages are minimum during lower feed and lower diameter drill. Hence, lower drill diameter, lower feed rate and medium speed are more suitable for drilling the hybrid composites.

scholarly journals AN EXPERIMENTAL STUDY ON FRICTION DRILLING OF ST12 STEEL

2014 ◽  
Vol 38 (3) ◽  
pp. 319-329 ◽  
Author(s):  
Mehmet Tuncay Kaya ◽  
Alaattin Aktas ◽  
Bertan Beylergil ◽  
Hamza K. Akyildiz
Keyword(s):  
Surface Temperature ◽  
Feed Rate ◽  
Thrust Force ◽  
Tool Material ◽  
Friction Angle ◽  
Drilling Speed ◽  
Workpiece Surface ◽  
Drilling Parameters ◽  
Friction Drilling ◽  
Contact Area Ratio

The aim of this study is to investigate the effects of drilling parameters such as friction angle, friction contact area ratio (FCAR), feed rate and spindle speed on workpiece surface temperature, thrust force and torque in friction drilling of ST12 material. The tool material is tungsten carbide coated with TiN treatment. Experimental results reveal that the thrust force and torque increases gradually with increasing friction angle, feed rate and FCAR. On the other hand, the thrust force and torque decreases with increasing drilling speed. It is found that drilling speed has an important effect on the workpiece surface temperature. As the drilling speed increases, the workpiece surface temperature increases. Increasing or decreasing the friction angle and FCAR has no significant effect on the workpiece surface temperature.

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