Finite Element Method Simulation of Drilling Process on Metal-Matrix Composites

2011 ◽  
Vol 188 ◽  
pp. 372-375
Author(s):  
H.L. Zhang ◽  
Jin Chen
Keyword(s):  
Finite Element ◽  
Feed Rate ◽  
Shear Failure ◽  
Thrust Force ◽  
Equivalent Stress ◽  
Damage Model ◽  
Cutting Speed ◽  
Finite Element Method Simulation ◽  
Drilling Process ◽  
Machining Processes

Drilling is one of the complex machining processes, which has been widely applied in the manufacturing area. In this paper, a 3D coupled thermo-mechanical finite element model was used for simulating the thrust force, torque and von Mises equivalent stress at different cutting conditions. The J-C damage model (shear failure) was used in conjunction with the J-C plasticity model, as well as the continuous adaptive remeshing technical. The results show that the thrust force and torque increase with the increasing of the cutting speed and feed rate, and the influence of the feed rate is more obviously.

scholarly journals Optimization for drilling process of metal-composite aeronautical structures

2021 ◽  
Vol 28 (1) ◽  
pp. 264-275
Author(s):  
Cristiano Devitte ◽  
Gabriel S. C. Souza ◽  
André J. Souza ◽  
Volnei Tita
Keyword(s):  
Feed Rate ◽  
Composite Laminates ◽  
Thrust Force ◽  
Cutting Speed ◽  
Statistical Design ◽  
Burr Formation ◽  
Drilling Process ◽  
Metal Composite ◽  
Aircraft Manufacturing ◽  
Delamination Factor

Abstract Metal-composite laminates and joints are applied in aircraft manufacturing and maintenance (repairing) using aluminum alloys (AA) and glass fiber-reinforced polymer (GFRP). In these applications, drilling has a prominent place due to its vast application in aeronautical structures’ mechanical joints. Thus, this study presents the influence of uncoated carbide drills (85C, 86C, H10N), cutting speeds (v c = 20, 40, and 60 m min−1), and feed rates (f = 0.05, 0.15, and 0.25 mm rev−1) on delamination factor, thrust force ( F t {F}_{\text{t}} ), and burr formation in dry drilling metal-composite laminates and joints (AA2024/GFRP/AA2024). Experiments were performed, analyzed, and optimized using the Box–Behnken statistical design. Microscopic digital images for delamination evaluation, piezoelectric dynamometer for thrust force acquisition, and burr analysis were considered. The major finding was that the thrust force during drilling depends significantly on the feed rate. Another significant factor was the influence of the drill type (combined or not with feed rate). In fact, it was verified that the feed rate and the drill type were the most significant parameters on the delamination factor, while the feed rate was the most relevant on thrust force. The cutting speed did not affect significantly thrust force and delamination factor at exit ( F da S ) \hspace{.25em}({F}_{{\text{da}}_{\text{S}}}) . However, the combination f × v c was significant in delamination factor at entrance   ( F da E ) \text{ }({F}_{{\text{da}}_{\text{E}}}) . Based on the optimized input parameters, they presented lower values for delamination factors ( F da E = 1.18 {F}_{{\text{da}}_{\text{E}}}=1.18 and F da S = 1.33 {F}_{{\text{da}}_{\text{S}}}=\hspace{.25em}1.33 ) and thrust force ( F t = 67.3 N {F}_{\text{t}}=67.3\hspace{.5em}\text{N} ). These values were obtained by drilling the metal-composite laminates with 85C-tool, 0.05 mm rev−1 feed rate, and 20 m min−1 cutting speed. However, the burrs at the hole output of AA2024 were considered unsatisfactory for this specific condition, which implies additional investigation.

scholarly journals Experimental Study on Drilling MDF with Tools Coated with TiAlN and ZrN

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 386 ◽  
Author(s):  
Krzysztof Szwajka ◽  
Joanna Zielińska-Szwajka ◽  
Tomasz Trzepiecinski
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Thrust Force ◽  
Medium Density Fiberboard ◽  
Cutting Speed ◽  
Piezoelectric Sensor ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Aesthetic Appearance

There is increasing use of wood-based composites in industry not only because of the shortage of solid wood, but above all for their better properties such as: strength, aesthetic appearance, etc., compared to wood. Medium density fiberboard (MDF) is a wood-based composite that is widely used in the furniture industry. The goal of the research conducted was to determine the effect of the type of coating on the drill cutting blades on the value of thrust force (Ft), cutting torque (Mc), cutting tool temperature (T) and surface roughness of the hole in drilling MDF panels. In the tests, three types of carbide drills (HW) were used: not coated, TiAlN coated and ZrN coated. The measurement of both the thrust force and the cutting torque was carried out using an industrial piezoelectric sensor. The temperature of the cutting tool in the drilling process was measured using an industrial temperature measurement system using a K-type thermocouple. It was found that the value of the maximum temperature of the tool in the drilling process depends not only on the cutting speed and feed rate, but also on the type of coating of the cutting tool. The value of both the cutting torque and the thrust force is significantly influenced by the value of the feed rate and the type of drill coating. The effect of varying plate density on the surface roughness of the hole and the variation of the value of the thrust force is also discussed. The results of the investigations were statistically analyzed using a multi-factorial analysis of variance (ANOVA).

scholarly journals Experimental Study on Drilling MDF with Tools Coated with TiAlN and ZrN

2019 ◽  
Author(s):  
Krzysztof Szwajka ◽  
Joanna Zielńska-Szwajka ◽  
Tomasz Trzepieciński
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Speed ◽  
Piezoelectric Sensor ◽  
Solid Wood ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Aesthetic Appearance

There is increasing use of wood-based composites in industry not only because of the shortage of solid wood, but above all for their better properties such as: strength, aesthetic appearance, etc. compared to wood. Medium density fibreboard (MDF) is a wood-based composite that is widely used in the furniture industry. The goal of the research conducted was to determine the effect of the type of coating on the drill cutting blades on the value of thrust force (Ft), cutting torque (Mc), cutting tool temperature (T) and surface roughness of the hole in drilling MDF panels. In the tests three types of carbide drills (HW) were used: not coated, TiAlN coated and ZrN coated. The measurement of both the thrust force and the cutting torque was carried out using an industrial piezoelectric sensor. The temperature of the cutting tool in the drilling process was measured using an industrial temperature measurement system using a K-type thermocouple. It was found that the value of the maximum temperature of the tool in the drilling process depends not only on the cutting speed and feed rate, but also on the type of coating of the cutting tool. The value of both the cutting torque and the thrust force is significantly influenced by the value of the feed rate and the type of drill coating. The effect of varying plate density on the surface roughness of the hole and the variation of the value of the thrust force is also discussed. The results of the investigations were statistically analysed using a multi-factorial analysis of variance (ANOVA).

Vibration Drilling Process on Al2024

2012 ◽  
Vol 445 ◽  
pp. 79-83 ◽  
Author(s):  
Saeed Amini ◽  
Alireza Fadaei Tehrani ◽  
A. Barani ◽  
H. Paktinat
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Ultrasonic Transducer ◽  
Cutting Speed ◽  
Peak Amplitude ◽  
Drilling Process ◽  
Machining Parameters ◽  
Drilling Tool ◽  
Vibration Drilling ◽  
Set Up

Vibration Drilling (VD) is one of the advance machining techniques to produce precision holes. In this study the vibration tool of drilling process is made with a new design while drilling tool vibrates by an ultrasonic transducer, it also rotates. The exerted vibration to tool has frequency of 20.6 kHz and low peak-to-peak amplitude. After preparation of process set-up, primary experiments were done on Al2024 workpiece. In these experiments , it was shown that thrust force in vibration drilling process is lower than in ordinary drilling (OD).Then the influence of some machining parameters include cutting speed and feed rate on thrust force in VD process studied and compared with OD process.

Preparation, Properties and Machinability Study of Luffa Fiber - Groundnut Shell Reinforced Epoxy Composite

2016 ◽  
Vol 852 ◽  
pp. 29-35
Author(s):  
R. Panneerdhass ◽  
A. Gnanavelbabu ◽  
K. Rajkumar
Keyword(s):  
Mechanical Properties ◽  
Polymer Composites ◽  
Feed Rate ◽  
Thrust Force ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Drilling Process ◽  
Structural Applications ◽  
Solid Carbide ◽  
Groundnut Shell

The need for eco-friendly materials and non-polluting processing techniques has made natural fibre reinforced polymer composites as potential candidates to replace GFRPS and CFRPS in semi structural applications. Ground nut shell and luffa fibre are easily available in the market at low cost. Polymer composites consisting of 30%, and 40% volume fractions of a hybrid reinforcement containing groundnut shell and luffa fibre in epoxy resin were fabricated by hand lay-up technique with varying process parameters, the variation in the mechanical properties such as tensile, compressive, flexure and impact strength are studied. The optimum mechanical properties were obtained in 40% of fiber volume fraction of treated fiber composites the machinability study was performed by drilling experiments using a drilling machine with drill tool dynamometer. Two input parameters, cutting speed and feed rate and the one output parameter, thrust force, were used for the drilling process. TiAlN coated solid carbide and hss drills were employed in the drilling experiments and a comparative study was made based on the output parameters. Solid carbide resulted in lower thrust force values and feed rate proved to be the most influential parameter on thrust force.

Simulation Analysis of RuT450 Drilling Force Based on LS-DYNA Gun Drilling

2018 ◽  
Vol 764 ◽  
pp. 271-278 ◽  
Author(s):  
H. Guo ◽  
W. Yang ◽  
L. Liu ◽  
X.K. Yang ◽  
Y.G. Wang ◽  
...  
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Equivalent Stress ◽  
Cutting Speed ◽  
Machining Process ◽  
Cutting Fluid ◽  
Drilling Process ◽  
Drilling Force ◽  
Workpiece Material ◽  
The Impact

Cutting force is one of the most important parameters in the machining process, it significantly influenced machining precision of the workpiece, power consumed in the machining process, wear of the cutting tools and so on. There are many factors that affect the cutting force, such as the performance of the workpiece material, cutting speed, usage of the cutting fluid, etc. Single factor variable method was used in this paper, RuT450 was used as workpiece, welded cemented carbide gun drill was used as cutting force and LS-DYNA was used as simulation platform to established the cutting simulation model to analyzed the impact of the cutting speed and feed rate to the drilling force. Simulation results show that, at the low speed drilling stage, drilling force increases with the increase of the feed rate and decreases with the increase of the rotation feed, from the stress cloud it could be seen that the equivalent stress near the drill tip reached the maximum in the drilling process.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

Fuzzy Logic in Hole Drilling of Composites

1994 ◽  
Author(s):  
Aditya Thadani ◽  
Athamaram H. Soni
Keyword(s):  
Fuzzy Logic ◽  
Fuzzy Logic Controller ◽  
Thrust Force ◽  
Cutting Speed ◽  
Research Data ◽  
Theoretical Research ◽  
Hole Drilling ◽  
Tool Geometry ◽  
Drilling Process ◽  
And Control

Abstract Experimental and theoretical research data was utilized in building a Fuzzy Logic Controller model applied to simulate the drilling process of composite materials. The objective is to have a better understanding and control of delamination of composites during the drilling process and at the same time to improve the hole finish by controlling fraying and splintering. By controlling the main issues in the drilling process such as feed rate, cutting speed, thrust force, and torque generated in addition to the tool geometry, it is possible to optimize the drilling process avoiding the conventionally encountered problems.

scholarly journals Optimization of Drilling Process Parameters Via Taguchi, TOPSIS and RSA Techniques

2017 ◽  
Vol 62 (3) ◽  
pp. 1803-1812 ◽  
Author(s):  
K. Shunmugesh ◽  
K. Panneerselvam
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Speed ◽  
High Strength ◽  
Drilling Process ◽  
Drill Bit ◽  
Influence Of Process Parameters ◽  
Light Trucks ◽  
Cfrp Composite

AbstractCarbon Fiber Reinforced Polymer (CFRP) is the most preferred composite material due to its high strength, high modulus, corrosion resistance and rigidity and which has wide applications in aerospace engineering, automobile sector, sports instrumentation, light trucks, airframes. This paper is an attempt to carry out drilling experiments as per Taguchi’s L27(313) orthogonal array on CFRP under dry condition with three different drill bit type (HSS, TiAlN and TiN). In this research work Response Surface Analysis (RSA) is used to correlate the effect of process parameters (cutting speed and feed rate) on thrust force, torque, vibration and surface roughness. This paper also focuses on determining the optimum combination of input process parameter and the drill bit type that produces quality holes in CFRP composite laminate using Multi-objective Taguchi technique and TOPSIS. The percentage of contribution, influence of process parameters and adequacy of the second order regression model is carried out by analysis of variance (ANOVA). The results of experimental investigation demonstrates that feed rate is the pre-dominate factor which affects the response variables.

Experiments of Drilling Titanium Alloy with Varying Operation Parameters

2017 ◽  
Vol 748 ◽  
pp. 254-258
Author(s):  
Chang Yi Liu ◽  
Bai Shou Zhang ◽  
Suman Shrestha
Keyword(s):  
Titanium Alloy ◽  
Feed Rate ◽  
Thrust Force ◽  
Maximum Amount ◽  
Spindle Speed ◽  
Drilling Process ◽  
Process Variables ◽  
Experimental Cutting ◽  
Operation Parameters ◽  
Titanium Alloy Ti6al4v

Drilling experiments of titanium alloy Ti6Al4V were conducted. Taking the speed and feed as the process variables, a set of experimental cutting forces are obtained and compared. From the experimental results it is concluded that within the experimental extent the thrust force and torque of drilling process rises with the feed rate. The lower spindle speed resulted in the greater amount of thrust. Feed rates have greater influence on the thrust force than the spindle speed. The combination of greater feed rate and lower spindle speed results in the maximum amount of thrust. However, combination of greater feed rate and spindle speed resulted in maximum amount of torque.

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