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.

Effects of Twist Drill Point Angle on Thrust Force and Delamination Factor in Hybrid Fiber Composites Drilling

2014 ◽  
Vol 564 ◽  
pp. 501-506 ◽  
Author(s):  
Mohd Azuwan Maoinser ◽  
Faiz Ahmad ◽  
Safian Shariff ◽  
Tze Keong Woo
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Polymeric Composite ◽  
Drilling Process ◽  
Twist Drill ◽  
Fiber Reinforced ◽  
Hybrid Fiber ◽  
Frp Composites ◽  
Delamination Factor ◽  
Drill Point

Drill point angle of twist drill has a significant effect on thrust force and delamination factor on drilled holes in fiber reinforced polymer (FRP) composites. In this study, three drill point angle of twist drill; 85°, 118° and 135° were used to drill holes in hybrid fiber reinforced polymeric composite (HFRP). HFRP composites were fabricated using vacuum infusion molding (VIM) technique. The test samples were cured at 90°C for two hours. In drilling process various drill point angle and feed rate were employed to investigate the effect of both parameters on thrust force and delamination factor when drilling the HFRP composite. The results showed that small drill point angle and low feed rate can reduce the thrust force leading to the reduction of damage factor at the holes entrance and exit.

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.

A Study of the Drilling Process

1974 ◽  
Vol 96 (4) ◽  
pp. 1207-1215 ◽  
Author(s):  
R. A. Williams
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Three Dimensional ◽  
Drilling Process ◽  
Two Dimensional ◽  
Twist Drill ◽  
Feed Velocity ◽  
Cutting Geometry ◽  
Drill Point ◽  
Finite Thrust

Drilling is a complex three dimensional cutting process yet it is possible to simulate the action of a two flute twist drill with two dimensional models provided consideration is given to the influence of the feed velocity on the cutting geometry at the drill point. Two models of chip formation and an indentation model are developed to simulate the action of the drill point. From these models equations are derived for the prediction of total torque and thrust given the cutting conditions, drill geometry, and an empirical factor which is related to the work material. Computed values of torque and thrust are shown to compare favorably with those obtained from drilling tests on an 0.45 percent C steel. The shape and magnitude of the wear zone about the chisel edge is estimated and it is shown that the observed finite thrust force as the feed rate approaches zero can be attributed to the “cutting” action of the chisel edge.

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.

Burr Height as Quality Indicator in Single Shot Drilling of Stacked CFRP/Aluminium Composite

2017 ◽  
Vol 744 ◽  
pp. 327-331 ◽  
Author(s):  
M Hafiz Hassan ◽  
Jamaluddin Abdullah ◽  
Abdus Samad Mahmud ◽  
Azwan Supran
Keyword(s):  
Helix Angle ◽  
Drilling Process ◽  
Single Shot ◽  
Hole Quality ◽  
Burr Height ◽  
Fractional Factorials ◽  
Reinforced Plastic ◽  
Carbon Fibre Reinforced Plastic ◽  
Metallic Parts ◽  
Exit Burr

In drilling metallic parts, burr height is one of the quality indicators that is used for hole quality assessment, and burr height need to be minimized for best hole quality. This is important because the induced exit burr height usually causes serious problem for further assembly of the stack up during the riveting and fasteners installation. This paper aims to establish an appropriate choice of drill geometry and drilling parameters to achieve a minimum or eliminate the burr height formation when drilling stacked Carbon Fibre Reinforced Plastic (CFRP)/aluminium 7075 T-6 composite in a single shot drilling process. The two levels of fractional factorials method was used to determine the optimum setting that give minimum burr height and the percentage of significance for each parameter in drilling a stack up materials was further analysed. The results revealed that burr height formation for stack up materials can be minimized at 15° of helix angle, 8° of primary clearance angle, 130°of point angle, 30° of chisel edge angle at spindle speed 2600 RPM and 0.05 mm/rev. A minimum burr height of 133.62 µm was found at these optimized combinations of parameters.

scholarly journals Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 891
Author(s):  
Numan Habib ◽  
Aamer Sharif ◽  
Aqib Hussain ◽  
Muhammad Aamir ◽  
Khaled Giasin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Speed Steel ◽  
Spindle Speed ◽  
Drilling Process ◽  
Hole Size ◽  
Hole Quality ◽  
Dry Drilling ◽  
Drilling Parameters ◽  
The Impact

Millions of holes are produced in many industries where efficient drilling is considered the key factor in their success. High-quality holes are possible with the proper selection of drilling process parameters, appropriate tools, and machine setup. This paper deals with the effects of drilling parameters such as spindle speed and feed rate on the chips analysis and the hole quality like surface roughness, hole size, circularity, and burr formation. Al7075-T6 alloy, commonly used in the aerospace industry, was used for the drilling process, and the dry drilling experiments were performed using high-speed steel drill bits. Results have shown that surface roughness decreased with the increase in spindle speed and increased with the increase in the feed rate. The hole size increased with the high spindle speed, whereas the impact of spindle speed on circularity error was found insignificant. Furthermore, short and segmented chips were achieved at a high feed rate and low spindle speed. The percentage contribution of each input parameter on the output drilling parameters was evaluated using analysis of variance (ANOVA).

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.

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%.

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