Comparison of conventional drilling and helical milling for hole making in Ti6Al4V titanium alloy under sustainable dry condition

Akula, Sneharika; Nayak, Sadvidya N.; Bolar, Gururaj; Managuli, Vishwanath

doi:10.1051/mfreview/2021010

Cited by 9 publications

(5 citation statements)

References 36 publications

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“…In sustainable drilling (dry condition), high-cutting speed and HSS tools are not suitable for use. HSS drill bits exhibit significant plastic deformation, which contributes to the tool's short life [8]. Hole 6 produces the best hole accuracy (exit) with an accuracy value of 99.41%.…”

Section: Hole Accuracy (Exit)mentioning

confidence: 99%

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Investigation of Ultrasonic-Assisted Drilling (UAD) Parameters For Hole Making Of Ti-6Al-4V Using Taguchi Method

Hussin

Sarip

Husain

2022

ARASET

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Ti-6Al-4V is widely used in high-tech industries due to its lightweight, high strength and corrosion resistance. Nevertheless, machining Ti-6Al-4V is very challenging given its low thermal conductivity. Ultrasonic Assisted Drilling (UAD) is one of the best machining techniques. In the manufacturing industry, hole-making is the final step before the end product is produced. The selection of parameters is crucial in obtaining accurate hole accuracy and a smooth surface finish. Cutting speed, feed rate, frequency, amplitude and tool material are important parameters in machining using UAD. Therefore, the optimisation of the combination of each of these parameters is pertinent in obtaining the best machining results. Screening parameters are widely used in optimising machining parameters. Taguchi is a statistical method that assists in optimising the experiments to be conducted. The expected findings from this study will facilitate the removal of insignificant parameters that could be used before proceeding to the actual runs. The impact of this study is to reduce costs, save time, as well as employ sustainable machining techniques.

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Section: Hole Accuracy (Exit)mentioning

confidence: 99%

“…The challenge in machining Ti-6Al-4V material is producing an end product with good hole accuracy due to the material's difficulty in machining and low thermal conductivity [8]. In the industry, the main factor used to evaluate the accuracy and quality of the drill hole is the value of the deviation of the diameter of the hole.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Ultrasonic-Assisted Drilling (UAD) Parameters For Hole Making Of Ti-6Al-4V Using Taguchi Method

Hussin

Sarip

Husain

2022

ARASET

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“…Moreover, using coolant helped to lower the surface damage and enhance fatigue life. Akula et al [29] assessed the helical milling and drilling process by considering the surface roughness, machining temperature, cutting forces, burr size, and hole diametrical accuracy. Helical milling process was advantageous as it helped to lower the burr size, cutting forces, and machining temperature and improve dimensional accuracy.…”

Section: Introductionmentioning

confidence: 99%

Machining Temperature, Surface Integrity and Burr Size Investigation during Coolant-Free Hole Milling in Ti6Al4V Titanium Alloy

et al. 2023

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Modern Aircraft structures use titanium alloys where the processing of holes becomes essential to assemble aerospace parts. Considering the limitations of drilling, the study evaluates the helical milling for hole processing in Ti6Al4V. The experimental evaluation was conducted by considering burr size, surface roughness, machining temperature, and microhardness under coolant-free conditions. The axial feed and cutting speed were varied at three levels, and nine experiments were conducted. The results exhibit a lower machining temperature during helical milling than during drilling. In addition, the helical milling helped to lower the surface roughness and size of the exit burrs. However, helical-milled holes showed higher subsurface microhardness than conventionally drilled holes. The process variables were influential on machining temperature magnitude. The highest recorded temperature of 234.7 °C was observed at 60 m/min of cutting speed and 0.6 mm/rev feed. However, the temperature rise did not affect the microhardness. Strain hardening associated with mechanical deformation was the primary mechanism driving the increase in microhardness. Helical-milled holes exhibited an excellent surface finish at lower axial feeds, while chatter due to tool deformation at higher feeds (0.6 mm/rev) diminished the surface finish. The surface roughness increased by 98% when the cutting speed increased to 60 m/min from 20 m/min, while a moderate increment of 28% was observed when the axial feed increased to 0.6 mm/rev from 0.2 mm/rev. Furthermore, the formation of relatively smaller burrs was noted due to significantly lower thrust load and temperature produced during helical milling.

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“…Drilling high-strength aluminium and titanium alloys typically results in trapped heat in holes that are difficult to dissipate due to the generated friction and chip formation between the drill tool and the aerospace structure. In addition, most drilled holes form burrs on both sides of the structure, which promote cracks’ formation and propagation and reduce fatigue life [ 5 , 6 , 7 , 8 , 9 ]. To remove holes’ burrs, a deburring post-processing operation is required for the hole edge finishing.…”

Section: Introductionmentioning

confidence: 99%

Elastomer-Based Visuotactile Sensor for Normality of Robotic Manufacturing Systems

et al. 2022

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Modern aircrafts require the assembly of thousands of components with high accuracy and reliability. The normality of drilled holes is a critical geometrical tolerance that is required to be achieved in order to realize an efficient assembly process. Failure to achieve the required tolerance leads to structures prone to fatigue problems and assembly errors. Elastomer-based tactile sensors have been used to support robots in acquiring useful physical interaction information with the environments. However, current tactile sensors have not yet been developed to support robotic machining in achieving the tight tolerances of aerospace structures. In this paper, a novel elastomer-based tactile sensor was developed for cobot machining. Three commercial silicon-based elastomer materials were characterised using mechanical testing in order to select a material with the best deformability. A Finite element model was developed to simulate the deformation of the tactile sensor upon interacting with surfaces with different normalities. Additive manufacturing was employed to fabricate the tactile sensor mould, which was chemically etched to improve the surface quality. The tactile sensor was obtained by directly casting and curing the optimum elastomer material onto the additively manufactured mould. A machine learning approach was used to train the simulated and experimental data obtained from the sensor. The capability of the developed vision tactile sensor was evaluated using real-world experiments with various inclination angles, and achieved a mean perpendicularity tolerance of 0.34°. The developed sensor opens a new perspective on low-cost precision cobot machining.

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Comparison of conventional drilling and helical milling for hole making in Ti6Al4V titanium alloy under sustainable dry condition

Cited by 9 publications

References 36 publications

Investigation of Ultrasonic-Assisted Drilling (UAD) Parameters For Hole Making Of Ti-6Al-4V Using Taguchi Method

Investigation of Ultrasonic-Assisted Drilling (UAD) Parameters For Hole Making Of Ti-6Al-4V Using Taguchi Method

Machining Temperature, Surface Integrity and Burr Size Investigation during Coolant-Free Hole Milling in Ti6Al4V Titanium Alloy

Elastomer-Based Visuotactile Sensor for Normality of Robotic Manufacturing Systems

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