Prozesskontrolle auch bei tiefen Bohrungen/Process control even for deep boreholes – Development of a mechatronic tool system for BTA deep hole drilling for compensation of straightness deviation

2020 ◽  
Vol 110 (01-02) ◽  
pp. 50-53
Author(s):  
Dirk Biermann ◽  
Berend Denkena ◽  
Benjamin Bergmann ◽  
Ivan Iovkov ◽  
Julian Frederic Gerken ◽  
...  
Keyword(s):  
Process Control ◽  
Industrial Applications ◽  
Hole Drilling ◽  
Deep Hole ◽  
Drilling Depth ◽  
Deep Hole Drilling ◽  
Parallel Measurement ◽  
Deep Boreholes ◽  
Machine Operator

Obwohl mit Tiefbohrverfahren in der Regel Bohrungen mit deutlich höherer Qualität als mit konventionellen Bohrverfahren hergestellt werden können, stellt der Mittenverlauf von Tiefbohrungen mit zunehmender Bohrungstiefe ein Qualitätsproblem dar. Die Prozesskontrolle im industriellen Einsatz wird zurzeit manuell und sehr zeitaufwendig durch den Maschinenbediener mithilfe eines mobilen Ultraschallsystems durchgeführt. Um eine einheitliche Qualität der Bauteile sicherzustellen und Kosten einzusparen, wird ein mechatronisches System zur Kompensation des Mittenverlaufs entwickelt.   Even though deep hole drilling methods can produce boreholes of higher quality than conventional drilling methods, the straightness deviation of the bore hole represents a quality problem, particularly with increasing drilling depth. Process control in industrial applications is currently performed manually and very time-consuming by the machine operator using a mobile ultrasonic system. In order to ensure a high quality of the components and to save costs, a mechatronic system for process-parallel measurement and influencing of the straightness deviation is being developed.

scholarly journals Study on super-long deep-hole drilling of titanium alloy

2018 ◽  
Vol 16 (1_suppl) ◽  
pp. 150-156 ◽  
Author(s):  
Zhanfeng Liu ◽  
Yanshu Liu ◽  
Xiaolan Han ◽  
Wencui Zheng
Keyword(s):  
Titanium Alloy ◽  
Material Properties ◽  
Experimental Approach ◽  
Chip Morphology ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Hole Axis

Introduction: In this study, the super-long deep-hole drilling of a titanium alloy was investigated. Methods: According to material properties of the titanium alloy, an experimental approach was designed to study three issues discovered during the drilling process: the hole-axis deflection, chip morphology, and tool wear. Results: Based on the results of drilling experiments, crucial parameters for the super-long deep-hole drilling of titanium alloys were obtained, and the influences of these parameters on quality of the alloy’s machining were also evaluated. Conclusions: Our results suggest that the developed drilling process is an effective method to overcome the challenge of super-long deep-hole drilling on difficult-to-cut materials.

Modelling of Dynamic System Characteristics of Deep Hole Drilling Process with Tools about Flexible Stifness

2014 ◽  
Vol 613 ◽  
pp. 333-339 ◽  
Author(s):  
Jarosław Zubrzycki ◽  
Antoni Świć ◽  
Marek Opielak
Keyword(s):  
Experimental Studies ◽  
The Self ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Drilling Parameters ◽  
Principal Assumption ◽  
System Characteristics

For an accepted physical model with allowance of cutting "on a trace" phenomena, the initial mathematical model for want of processing deep hole is considered. In the work has been presented principal assumption to modeling of vibrating process of deep hole drilling. To implement the process were used specially developed construction of waveguide transducer to generate the self-excited vibrations. The use of the transducer was aimed at increasing the efficiency of the process and improve the quality of performed hole. Performed model was used to process numerical researches to obtain the amplitude-phase characteristics of the drilling parameters. Then they were compared with the appropriate characteristics obtained from experimental studies.

The Study on Evaluation of Hybrid Drilling Command under Deep Hole Drilling

2012 ◽  
Vol 579 ◽  
pp. 219-226
Author(s):  
Jen Ching Huang ◽  
Wei Piao Wu
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Small Hole ◽  
Hole Drilling ◽  
Deep Hole ◽  
Cnc Machine ◽  
Drilling Depth ◽  
Deep Hole Drilling ◽  
Peck Drilling ◽  
Custom Macro

The hybrid drilling command was proposed in this study. The hybrid drilling command is established by combined the merit of G73 (high speed peck drilling cycle) and G83 (small hole peck drilling cycle) using custom macro command. The concept of hybrid drilling command is to divide the total drilling depth into several distances and its distance is shortened gradually. The drilling chip is breaking with the G73 in the distance between each one and banishing from the hole with the G83 after drilling a distance each time. The evaluation on the merit of hybrid drilling command was carried out by deep hole drilling test on CNC machine center. After experiments, the hybrid drilling command can reduce wearing, extending the tool life of the driller and shorten processes time.

Iterative Learning Method for Drilling Depth Optimization in Peck Deep-Hole Drilling

2018 ◽  
Vol 140 (12) ◽  
Author(s):  
Ce Han ◽  
Ming Luo ◽  
Dinghua Zhang ◽  
Baohai Wu
Keyword(s):  
Iterative Learning ◽  
Hole Drilling ◽  
Machining Efficiency ◽  
Learning Method ◽  
Deep Hole ◽  
Drilling Depth ◽  
Deep Hole Drilling ◽  
Modified Newton’S Method ◽  
Peck Drilling ◽  
Chip Removal

Due to the enclosed chip evacuation space in deep hole drilling process, chips are accumulated in drill flutes as drilling depth increases, resulting in the increase of drilling torque and lead to drill breakage. Peck drilling is a widely used method to periodically alleviate the drilling torque caused by chip evacuation; the drilling depth in each step directly determines both drill life and machining efficiency. The existing drilling depth optimization methods face problems including low accuracy of the prediction model, the hysteresis of signal diagnosis, and onerous experiments. To overcome these problems, a novel drilling depth optimization method for peck drilling based on the iterative learning optimization is proposed. First, the chip evacuation torque coefficients (CETCs) are introduced into the chip evacuation torque model to simplify the model for learning. Then, the effect of chip removal process in peck drilling on drilling depth is analyzed. The extended depth coefficient by chip removal (EDCbCR) is introduced to develop the relationship between the extended depth in each drilling step and drilling depth. On the foundation of the modeling above, an iterative learning method for drilling depth optimization in peck drilling is developed, in which a modified Newton's method is proposed to maximize machining efficiency and avoid drill breakage. In experiments with different cutting parameters, the effectiveness of the proposed method is validated by comparing the optimized and measured results. The results show that the presented learning method is able to obtain the maximum drilling depth accurately with the error less than 10%.

scholarly journals Investigation of Chip Deformation and Breaking with a Staggered Teeth BTA Tool in Deep Hole Drilling

Metals ◽  
2019 ◽  
Vol 9 (1) ◽  
pp. 46
Author(s):  
Xu-Bo Li ◽  
Jian-Ming Zheng ◽  
Yan Li ◽  
Ling-Fei Kong ◽  
Wei-Chao Shi ◽  
...  
Keyword(s):  
Chip Thickness ◽  
Contact Length ◽  
Hole Drilling ◽  
Drilling Process ◽  
Rake Face ◽  
Deep Hole ◽  
Drilling Depth ◽  
Deep Hole Drilling ◽  
Chip Breaker ◽  
Chip Breaking

The problem of chip breaking and evacuation is the key point of staggered teeth boring and trepanning association (BTA) drilling. The factors that influence chip breaking with staggered teeth BTA deep hole drilling are analyzed by using the chip bending deformation mechanism for chip formation and flow through the rake face and chip breaker. This study investigated the distribution and variation of chip deformation and breaking along drilling conditions, with respect to drilling radius, drilling process parameters, tool wear, and chip breaker geometric parameters. The results show that the tool-chip contact length is about 1.65 times the chip thickness in staggered teeth BTA drilling. The cutting radius of the teeth has a considerable influence on the chip thickness. Compared with the drilling speed, the feed has a greater impact on chip deformation and breaking, and the chip thickness and strain increase with increased feed. Increased drilling depth and tooth wear aggravates the friction state between the chip and the rake face, augments chip thickness and tool-chip contact length, and increases the chip’s strain increment. As the width of chip breaker decreases and the height increases, the chip strain increases and the breaking conditions are improved.

Analysis of Deep Hole Drilling in Presence of Electromagnetic Field Using Taguchi Technique

2014 ◽  
Author(s):  
F. Najarian ◽  
M. Y. Noordin ◽  
F. M. Nor ◽  
D. Kurniawan
Keyword(s):  
Electromagnetic Field ◽  
Spindle Speed ◽  
Hole Drilling ◽  
Deep Hole ◽  
Taguchi Technique ◽  
Deep Hole Drilling ◽  
Machining Quality ◽  
Control Factors ◽  
Cylindricity Error

Electromagnetic field assisted machining is potential and is of particular interest to be explored to improve machining quality with minimum environmental effect. In this study, the effect of electromagnetic field on tool and workpiece is analyzed along with the effects of presence of drilling bush, feedrate, and spindle speed to the quality of hole for deep hole drilling. The effect of these control factors to the drilled hole’s cylindricity error and roundness error was determined using Taguchi technique. L16 orthogonal array design of experiments was used, with regression model was calculated and tested using analysis of variance. Spindle speed was found to be the only significant factor, with other factors did not give significant effect to roundness or cylindricity, except for tool magnetization which affected cylindricity. Issues with magnetization system are likely hinder the magnetic field to exhibit potential to improve machining quality, and should be addressed for future study.

Modified DLC-Coated Guide Pads for BTA Deep Hole Drilling Tools

2010 ◽  
Vol 438 ◽  
pp. 195-202 ◽  
Author(s):  
Dirk Biermann ◽  
Nadine Kessler ◽  
Thorsten Upmeier ◽  
Thomas Stucky
Keyword(s):  
Surface Quality ◽  
Borehole Wall ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Forming Process ◽  
Workpiece Material ◽  
Drilling Depth ◽  
Deep Hole Drilling ◽  
Drilling Tools

The BTA (Boring and Trepanning Association) deep hole drilling process is commonly used to machine boreholes with a large drilling depth-to-diameter ratio (l/D) and outstanding workpiece quality. The asymmetric tool design leads to a nonzero radial component of the cutting force and the passive force, which are conducted to the borehole wall by so-called guide pads. These guide pads smooth the borehole wall by a forming process and improve the surface quality. Processes, that machine materials with a high adhesion tendency, such as high alloy stainless steel, suffer from poor surface quality in the borehole and the adhesion from the workpiece material on the guide pads. In this paper modified Diamond-Like-Carbon (DLC) coated guide pads for BTA deep hole drilling tools are investigated. The scope of the experiments was the reduction of the adhesion by reducing the friction coefficient of the guide pads, as well as the improvement of the quality of the borehole wall.

Deep Hole Drilling Technique (DHD)

2019 ◽  
Vol 88 (6) ◽  
pp. 485-488
Author(s):  
Shinji KAWAI ◽  
Takuya NAGAI ◽  
Shigetaka OKANO
Keyword(s):  
Hole Drilling ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Drilling Technique
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