The Effect of Spindle Speed and Feed Rate on Hole Diameter of High-Speed Micro-Drilling for Micro-Screen Manufacture

2020 ◽  
Vol 402 ◽  
pp. 125-130
Author(s):  
Muhammad Tadjuddin ◽  
Suhaeri ◽  
Muhammad Dirhamsyah ◽  
Aulia Udink ◽  
Fatur Rahmatsyah
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Tool Material ◽  
Spindle Speed ◽  
Machining Process ◽  
Drilling Process ◽  
Machining Parameters ◽  
A Value ◽  
Micro Drilling ◽  
Hole Dimensions

The micro-drill is one of the manufacturing processes that is developing, especially in the electronics, aerospace, pharmaceutical, and automotive industries. This paper describes the results of the high-speed microdrill process in stainless steel. The drilling process is used to make the micro screen. The cutting tool material is tungsten carbide with a diameter of 0.2 mm. Drilling holes arranged in a honeycomb configuration. The machining parameters used are spindle speed of 20,000 rpm, 22,000 rpm, 24,000 rpm, and feed rate of 1 mm/min, 1.5 mm/min, 2 mm/min. Micro-drilling holes are visually analyzed using a Scanning Electron Microscope (SEM) to measure the accuracy of the hole dimensions. The results of the machining process found that the most significant deviation of the hole dimension size with a value of 0.276 mm occurred at a spindle speed of 20,000 rpm with a feed of 1 mm/min. While the deviation of the smallest hole size with a value of 0.2019 mm occurred at a spindle speed of 24,000 rpm with a feed of 2 mm/min, these results conclude that the accuracy of the hole dimensions will increase in proportion to the increase in spindle speed and feeding.

scholarly journals Optimization of CFRP Micro Drilling Parameter using 2-Level Factorial Method Towards Thrust Force

2019 ◽  
Vol 9 (2) ◽  
pp. 4487-4491
Keyword(s):  
Material Properties ◽  
Feed Rate ◽  
Optimum Parameter ◽  
Thrust Force ◽  
Weight Ratio ◽  
Spindle Speed ◽  
Material Behavior ◽  
Machining Process ◽  
Drilling Process ◽  
Micro Drilling

Carbon Fiber Reinforced Polymer (CFRP) is extensively used in aircraft and automotive industries due to it exceptional material properties such as high strength to weight ratio and corrosion resistance. Nevertheless, micro drilling process of CFRP material poses various challenge as it has irregular material properties along the structure. High cutting force which lead to poor hole quality is one of the issues that always occur when drilling this material. Hence, the understanding on the relationship between process parameter and material behavior is vital to achieve optimum performance of machining process. The experiment was carried out using 2-level factorial design with variable spindle speed range of 8,000 – 12,000 rpm and feed rate range of 0.01-0.015 mm/rev. Micro drill bit with diameter of 0.9 mm was used and new fresh drill were used for every run to avoid tool wear effect. As a result, lower thrust force of 6.3742 N is obtained from the combination of spindle speed 10k rpm and feed rate 0.0125 N. Therefore, it can be concluded that, optimum parameter falls between the range of 8,000 – 12,000 rpm of spindle speed and 0.01-0.015 mm/rev of feed rate. Validation of the optimum parameter suggested from 2-level factorial which are 8,000 rpm and 0.01 mm/rev is executed. The final result obtained shows 4.5% of error from targeted value and this result is absolutely acceptable and portray the reliability of the experiment.

Investigation of Burr in High Speed Microdrilling

2013 ◽  
Vol 278-280 ◽  
pp. 389-392
Author(s):  
Mohammad Yeakub Ali ◽  
A. R. Mohamed ◽  
Nor Fadila ◽  
Noor Hannah
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Influential Factors ◽  
Spindle Speed ◽  
Drilling Process ◽  
Burr Height ◽  
Optimum Parameters ◽  
Micro Drilling ◽  
Burr Width ◽  
The Relationship

This paper discusses burr in microdrilling that affect forms and functions of parts. The effects of microdrilling parameters on burr length and width are identified. The experiment was conducted using Mikrotools DT110 machine with one millimetre diameter of HSS on copper workpiece. Burr heights in terms of burr length and burr width were measured by using scanning electron microscope. The data was analyzed using Taguchi method to find the optimum micro-drilling process parameter for minimizing the burr height. The relationship among spindle speed, feed rate and burr has been developed. It is found that feed rate is the most influential factors on the burr height. The desirability of getting the minimum burr height is 72% and the optimum parameters are 30000 rpm spindle speed and 0.2 mm/min feed rate.

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.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

A Parametric Analysis on Micro-Drilling Process With Nanofluid Minimum Quantity Lubrication

2013 ◽  
Author(s):  
Jung Soo Nam ◽  
Dae Hoon Kim ◽  
Sang Won Lee
Keyword(s):  
Feed Rate ◽  
Parametric Analysis ◽  
Large Diameter ◽  
Minimum Quantity Lubrication ◽  
Drilling Process ◽  
Machining Parameters ◽  
Minimum Quantity ◽  
Micro Drilling ◽  
Nanofluid Minimum Quantity Lubrication ◽  
Thrust Forces

This paper presents a parametric analysis on microdrilling process using nanofluid minimum quantity lubrication (MQL). In this paper, the effects of several machining parameters such as a feed rate, rotational speed and drill diameter on micro drilling performances are investigated under various lubrication conditions — compressed air lubrication, pure MQL and nanofluid MQL. For nanofluid MQL, nanodiamond particles are used with the volumetric concentration of 4 %. A series of microdrilling experiments are carried out in the miniaturized machine tool system. The experimental results show the nanofluid MQL can be effective for reducing average drilling torques and thrust forces, in particular, at relatively low feed rate (10 mm/min) and low spindle speed (30,000 RPM) in the case using the drill with small diameter (0.1 mm). Meanwhile, in the case using the drill with large diameter (0.5 mm), the nanofluid MQL may not be effective for reducing average torques and thrust forces.

scholarly journals Effects of Parameters of Machining on Cutting Force and Roughness when Machining AZ31 Magnesium Alloy

2019 ◽  
Vol 9 (2) ◽  
pp. 4756-4758
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Machining Process ◽  
Mg Alloy ◽  
Machining Parameters ◽  
Machining Processes

This project was done to learn the effects of cutting parameters on cutting force and roughness (surface roughnes) of AZ31 magnesium (Mg) alloy. Machining parameters involved in this project are cutting speed, feed rate, and lubrication methods. Deckel Maho DMU 50 eVolution high speed milling machine was using and uncoated carbide button insert was used as the cutting tool. Cutting force was measured during the milling process and roughness was measured after that and cleaning process to ensure no interference that would conflicted the results. The best machining parameters identified when feed rate at 0.05 mm per tooth, cutting speed are at 600 m per min, and minimum quantity lubrication was applied during the machining process. From analysis of variance (ANOVA) table generated by Minitab software, this project can conclude that feed rate, cutting speed, and lubrication methods are significant to cutting force and roughness when machining AZ31 Mg Alloy Therefore, the relationship of surface roughness and cutting force should be taken as a major key point in machining processes. In the automotive field, magnesium was used to fabricate an engine that place at front body due to reduce the weight of vehicle. This design can increase performance and balancing of weight [1].

Effect of Machining Parameters on Hole Accuracy and Burr Formation in Micro-Drilling of Brass

2020 ◽  
Vol 402 ◽  
pp. 73-80
Author(s):  
Teuku Firsa ◽  
Muhammad Tadjuddin ◽  
Aulia Udink ◽  
Iskandar Hasanuddin
Keyword(s):  
Feed Rate ◽  
Digital Camera ◽  
Spindle Speed ◽  
Hole Diameter ◽  
Burr Formation ◽  
Work Piece ◽  
Machining Parameters ◽  
Burr Height ◽  
Micro Drilling

Micromachining technology is a challenge in industrial production to meet the demand for components for machinery. In this research, a study of the best parameters was required to produce the best hole accuracy and the lowest burr formation in the inlet and exit holes using micro-drilling. The work-piece material and cutting tool used respectively was a brass plate with a thickness of 0.5 mm and a micro drill with a diameter of 0.2 mm commonly used for electronic PCBs. The quality of holes was measured and observed by using a stereomicroscope (optical equipment). This microscope can zoom up to 50x objects to facilitate measurement. The microscope was attached by using a digital camera type YW-200 so that the object of observation could be measured using a computer. The result shows that the largest deviation of hole diameter (0.217 mm) occurred at a spindle speed of 14,000 rpm with the lowest feed rate (5 mm/min). Meanwhile, the smallest deviation of hole diameter (0.202 mm) occurred at a spindle speed of 20,000 rpm with a maximum feed rate of 10 mm/min. The maximum burr height (0.050 mm) occurred at a spindle speed of 17,000 rpm and a feed rate of 10 mm/min. In addition, the minimum burr height (0.038 mm) occurred at a spindle speed of 14,000 rpm and a feed rate of 5 mm/min. Therefore, it can be concluded that the deviation of hole diameter was inversely proportional to the spindle speed, and the height of the burr formation was directly proportional to the feed rate.

scholarly journals Influence of Cutting Parameters to Surface Area Roughness in Dimple Machining Using Milling Process

2021 ◽  
Vol 18 (3) ◽  
Author(s):  
M.A. Hanafiah ◽  
A.A. Aziz ◽  
A.R. Yusoff
Keyword(s):  
Surface Area ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Ball End Mill

Surface quality is among the predominant criterion in measuring machining process performance, including milling. It is extremely dependent on the process variable, such as cutting parameters and cutting tool conditions. The main intention of this research work is to study the effect of the milling machining parameters, including depth of cut, spindle speed, feed rate as well as machining pattern to the final surface area roughness of the fabricated dimple structure. The concave profile of the dimple is machined at the right angle to a flat Al6061 specimen using a ball end mill attached to a 3-axis CNC milling machine, and the surface area of the concave profile is measured using 3D measuring laser microscope. It is observed that surface area roughness reacts with the spindle speed and feed rate with different tool sizes. Based on the result gained, the work has successfully characterised the influence of studied milling parameters on the dimple surface area roughness, where within the range of the studied parameter, the surface area roughness varies only less than 2.2 μm. The research work will be continued further on the incline milling technique and micro size ball end mill.

Analysis of Machining Parameters in Turning Operation on Duplex 2205 by using RSM for Vehicle Structure

2019 ◽  
Vol 11 (1) ◽  
Author(s):  
V. Vijayan ◽  
B. Sureshkumar ◽  
G. Sathishkumar ◽  
R. Yokeshwaran
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Removal Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Operation ◽  
Feed Force ◽  
Cylindrical Parts

Turning is the machining process carried out to make cylindrical parts. Since the process is economical and the flexibility of turning operation is high, the process has become highly versatile among the industrial scenario. The design of experiments concept along with response surface methodology is used to analyze the machining parameters such as spindle seed, feed rate and depth of cut, of the turning operation. Three levels of spindle speed, feed rate and depth of cut are used as input parameters and their corresponding responses such as material removal rate (M.R.R), surface roughness, feed force, thrust force and cutting force are considered as the output parameters. The main aim of this experimentation process is to identify the optimal process parameters to get high M R R and low surface roughness. During high spindle speed, the M R R is high and vice versa. Surface roughness is high when its corresponding spindle speed and depth of cut is high. A high spindle speed, the chip formation is continuous whereas in medium speed, discontinuous chip is formed. M.R.R is high when spindle speed, depth of cut and feed rate are high.

Modeling of Surface Roughness in Drilling of MDF Panels

2015 ◽  
Vol 766-767 ◽  
pp. 831-836 ◽  
Author(s):  
T.N. Valarmathi ◽  
K. Palanikumar ◽  
S. Sekar
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Forces ◽  
Spindle Speed ◽  
Machining Process ◽  
Drilling Process ◽  
Composite Panels ◽  
Wood Composite ◽  
Control Parameters ◽  
Input Control

Medium density fiberboard wood composite panels are preferred for many domestic and industrial applications over the natural wood because of their high-quality properties. The aesthetic appearance of wood composites makes them suitable for interior and exterior construction works. Among various machining process, drilling is the most frequently used machining operation in the furniture industry in assembly of panel products. During drilling process the drill exhibits cutting forces such as thrust force and torque. The surface quality of the drilled holes are mainly affected by the cutting forces developed during drilling process which causes surface roughness, delamination like damages which leads to the rejection of the final product. Hence the reduction of the drilling defects, the control of the cutting forces is very much essential. The drilling parameters play an important role in controlling the cutting forces. The objective of this work is to study the influence of input control parameters such as spindle speed, feed rate and point angle on surface roughness in drilling of MDF panels to obtain the optimal cutting conditions. In the present study the drilling experiments are conducted using Taguchi design of experiments on wood composite panels with high speed steel (HSS) twist drills with different point angles on vertical machining center using at dry condition. Three levels and three factors are considered. Taguchi L27 orthogonal array is used. Response surface methodology is used to develop a mathematical model to predict the influence of input control parameters on cutting forces. Analysis of variance is used to check the adequacy of the model. Surface roughness is increased with an increase of feed rate and drill point angle and decreased with an increase in the spindle speed. It is revealed that high spindle speed with low feed rate and smaller point angle combination gives better results in drilling of wood composite panels.

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