Influence of Machining Parameters of the Drilling Polymers UHMW-PE and PTFE

2015 ◽  
Vol 1120-1121 ◽  
pp. 1297-1301 ◽  
Author(s):  
Breno Ferreira Lizardo ◽  
Luciano Machado Gomes Vieira ◽  
Juan Carlos Campos Rubio ◽  
Marcelo Araújo Câmara

Over the years, with the increasing development of engineering materials, the emergence of new composites, fiber metal laminated, biomaterials, metal alloys etc., and with demand for products less expensive, less polluting and more efficient, the manufacturing engineering also needs to develop to be able to process these new materials. Materials and tool geometries, intelligent mechanisms, modular machines, also follow this setting. To that end, this work comes to raise the main parameters that influence in the hole quality surface of finished product. Were used two polymeric materials, ultra high molecular weight polyethylene (UHMW-PE) and polytetrafluoroethylene (PTFE), two feed rates, three rotations and three tool geometries, allowing to identify which of these parameters have greater influence on the thrust force and the characteristics of the finished product and dimensional deviation.

2019 ◽  
Vol 56 (1) ◽  
pp. 245-251
Author(s):  
Florin Susac ◽  
Valentin Tabacaru ◽  
Virgil Gabriel Teodor ◽  
Nicusor Baroiu

Drilling of polymeric materials can be challenging when holes are produced in large scale due to the necessity of controlling the holes quality. This paper presents the effect of machining parameters on the hole quality, in terms of surface roughness and circularity error, in drilling of high density polyethylene, polyamide and polyacetale. The analysis of variance was performed in order to assess the significance of cutting parameter on the hole quality parameters. The experimental results indicate that different cutting conditions are to be employed in order to achieve the optimum surface roughness and circularity.


2021 ◽  
Vol 5 (7) ◽  
pp. 189
Author(s):  
Muhammad Hafiz Hassan ◽  
Jamaluddin Abdullah ◽  
Gérald Franz ◽  
Chim Yi Shen ◽  
Reza Mahmoodian

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.


2014 ◽  
Vol 590 ◽  
pp. 294-298
Author(s):  
Pichai Janmanee ◽  
Somchai Wonthaisong ◽  
Dollathum Araganont

In this study, effect of machining parameters and wear mechanism in milling process of mold steel AISI-P20 and AISI-1050, using 10 mm twin flute type end mill diameter. The experimental results found that characteristics of milling surfaces and wear of the mill end were directly influenced by changes of parameters for all test conditions. As a result, the quality of milling surfaces also changed. However, mould steels which had the good quality surface is AISI-1050, with roughnesses of 2.120 μm. Quality milling surfaces were milled by using the most suitable parameter feed rate of 45 mm/min, a spindle speed of 637 rpm and a cut depth level of 3 mm, for both grades. Moreover, material removal rate and duration of the milling process, the milling end mills affect wear of the edge in every bite when the feed rate is low, high speed and level depth of cut at least. It was found that limited wear less will affect the surface roughness (Ra) represents the good quality surface.


2009 ◽  
Vol 3 (5) ◽  
Author(s):  
Azlan Abdul Rahman ◽  
Azuddin Mamat ◽  
Abdullah Wagiman

Author(s):  
Ian L. Hosier ◽  
Alun S. Vaughan

Polymer science is, of course, driven by the desire to produce new materials for new applications. The success of materials such as polyethylene, polypropylene, and polystyrene is such that these materials are manufactured on a huge scale and are indeed ubiquitous. There is still a massive drive to understand these materials and improve their properties in order to meet material requirements; however, increasingly polymers are being applied to a wide range of problems, and certainly in terms of developing new materials there is much more emphasis on control. Such control can be control of molecular weight, for example, the production of polymers with a highly narrow molecular weight distribution by anionic polymerization. The control of polymer architecture extends from block copolymers to other novel architectures such as ladder polymers and dendrimers. Cyclic systems can also be prepared, usually these are lower molecular weight systems, although these also might be expected to be the natural consequence of step-growth polymerization at high conversion. Polymers are used in a wide range of applications, as coatings, as adhesives, as engineering and structural materials, for packaging, and for clothing to name a few. A key feature of the success and versatility of these materials is that it is possible to build in properties by careful design of the (largely) organic molecules from which the chains are built up. For example, rigid aromatic molecules can be used to make high-strength fibres, the most highprofile example of this being Kevlar®; rigid molecules of this type are often made by simple step-growth polymerization and offer particular synthetic challenges as outlined in Chapter 4. There is now an increasing demand for highly specialized materials for use in for example optical and electronic applications and polymers have been singled out as having particular potential in this regard. For example, there is considerable interest in the development of polymers with targeted optical properties such as second-order optical nonlinearity, and in conducting polymers as electrode materials, as a route towards supercapacitors and as electroluminescent materials. Polymeric materials can also be used as an electrolyte in the design of compact batteries.


2020 ◽  
pp. 002199832095774
Author(s):  
Eduardo Pires Bonhin ◽  
Sarah David-Müzel ◽  
Manoel Cléber de Sampaio Alves ◽  
Edson Cocchieri Botelho ◽  
Marcos Valério Ribeiro

The use of fiber metal laminates (FML) in aeronautics components has been increased in the last years, mainly due to the gain in mechanical properties combined with low specific mass. However, in the assembly of these materials on the structures to which they will be attached, mechanical screwing is still the main method used, which requires the performance of drilling processes. Something it is very complicated for these materials and can cause damage that compromises the performance. Therefore, this work aims to approach and summarize the evolution of the mechanical drilling process on FML developed in the last years. By the work, the main problems that occur during the drilling of these materials are punctually approached, such as delamination, burr formation, dimensional error, poor roughness, and tool wear. In addition, it is presented how these problems are affected by the machining parameters (cutting parameters, geometry, material/coating tool, and cutting environment), as well as suggestions for minimizing process problems. Thus, the article intends to provide as much information as possible available in the literature, seeking to help researchers gain a comprehensive view of the mechanical drilling of fiber metal laminates.


1994 ◽  
Vol 116 (4) ◽  
pp. 475-481 ◽  
Author(s):  
S. Jain ◽  
D. C. H. Yang

Composite laminates in significant numbers are rendered unacceptable due to delamination that occurs during the drilling operation. Thrust generated during the drilling operation is identified as responsible for delamination. Expressions developed for critical thrusts and critical feed rates, by modeling the delamination zone as an elliptical plate in unidirectional laminates, appear to be fairly accurate. It has been demonstrated that the critical thrusts and feed rates obtained for unidirectional laminates can be conservatively used for multi-directional laminates. With regard to the tool geometry, the chisel edge width appears to be the single most important factor contributing to the thrust force and hence delamination. A diamond-impregnated tubular drill tool was designed and tested. This tool resulted in a much smaller thrust and much better hole quality as compared with the standard twist drills.


2020 ◽  
pp. 089270572093916
Author(s):  
Nafiz Yaşar ◽  
Mustafa Günay ◽  
Erol Kılık ◽  
Hüseyin Ünal

In this study, the mechanical and machinability characteristics of chitosan (Cts)-filled polypropylene (PP) composites produced by injection molding method were analyzed. Uniaxial tensile, impact, hardness, and three-point flexural tests were used to observe the influence of Cts filler on the mechanical behavior of PP. For the machinability analysis of these materials, drilling experiments based on Taguchi’s L27 orthogonal array were performed using different drill qualities and machining parameters. Then, machining conditions are optimized through grey relational analysis methodology for machinability characteristics such as thrust force and surface roughness obtained from drilling tests. The results showed that tensile, flexural strength, and percentage elongation decreased while impact strength increased with adding the Cts filler to PP. Moreover, it was determined that the tensile and flexural modulus of elasticity increased significantly and there was a slight increase in hardness. Thrust forces decreased while surface roughness values increased when the Cts filler ratio and feed rate was increased. The optimal machining conditions for minimizing thrust force and surface roughness was obtained as PP/10 wt% Cts material, uncoated tungsten carbide drill, feed rate of 0.05 mm/rev, and cutting speed of 40 m/min. In this regard, PP composite reinforced by 10 wt% Cts is recommended for industrial applications in terms of both the mechanical and machinability characteristics.


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