Evaluating Hole Quality in Drilling of Al 6061 Alloys

Uddin, Md. Sharif; Basak, A.K.; Pramanik, Alokesh; Singh, Sunpreet; Królczyk, Grzegorz M.; Prakash, Chander

doi:10.3390/ma11122443

Cited by 87 publications

(35 citation statements)

References 27 publications

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“…The analysis of S/N ratio shows that the poly-drill head also performs better than one-shot drilling, as the best combination of parameters can be obtained at DT level 2, CS level 1, and FR level 1. Lower FR facilitated the slower insertion of the tool, which allowed a stable and jerk-free performance as the cutting edges of the tool removed the material with smaller chip thickness; consequently, the HS shows less dimensional error [34]. Furthermore, at higher CS, chatter and drilling temperature appeared to be more, which might affect the size of the hole [29].…”

Section: Optimization Of Drilling Conditions Using Taguchi Analysismentioning

confidence: 99%

Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach

Aamir

Tolouei‐Rad

et al. 2020

Materials

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In industries such as aerospace and automotive, drilling many holes is commonly required to assemble different structures where machined holes need to comply with tight geometric tolerances. Multi-spindle drilling using a poly-drill head is an industrial hole-making approach that allows drilling several holes simultaneously. Optimizing process parameters also improves machining processes. This work focuses on the optimization of drilling parameters and two drilling processes—namely, one-shot drilling and multi-hole drilling—using the Taguchi method. Analysis of variance and regression analysis was implemented to indicate the significance of drilling parameters and their impact on the measured responses i.e., surface roughness and hole size. From the Taguchi optimization, optimal drilling parameters were found to occur at a low cutting speed and feed rate using a poly-drill head. Furthermore, a fuzzy logic approach was employed to predict the surface roughness and hole size. It was found that the fuzzy measured values were in good agreement with the experimental values; therefore, the developed models can be effectively used to predict the surface roughness and hole size in multi-hole drilling. Moreover, confirmation tests were performed to validate that the Taguchi optimized levels and fuzzy developed models effectively represent the surface roughness and hole size.

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Section: Optimization Of Drilling Conditions Using Taguchi Analysismentioning

confidence: 99%

Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach

Aamir

Tolouei‐Rad

et al. 2020

Materials

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“…The use of a feed rate of 200 mm/min generates the lowest Ra values. This may be because a smaller chip is generated, as Uddin et al [23] indicate in their results. Increases in feed rate result in poorer surface quality.…”

Section: Resultsmentioning

confidence: 90%

One-Shot Drilling Analysis of Stack CFRP/UNS A92024 Bonding by Adhesive

et al. 2019

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The use of adhesive layers can improve the properties and reduce the defects produced in the interfaces. This provides adherence to the structure, adapting the joining surfaces and avoiding spaces between the layers. However, the presence of the adhesive can potentiate the defects caused during drilling. In turn, a loss of adhesive in the interface can occur during machining affecting the final structure. This work has followed a conventional OSD strategy in CFRP and UNS A92024 aluminium sheet stacking with adhesive. A series of dry drilling tests have been developed with different cutting conditions and new noncoated WC-Co helical cutting tools. Analysis of Variance (ANOVA) statistical analyses and surface response models have been applied to determine the mechanical behaviour in the holes. For this purpose, the dimensional deviation, surface quality, and adhesive loss in the interface in relation to the number of holes have been considered. A combination of cutting parameters that minimizes the evaluated defects has been found. Diametric deviations and surface qualities below 2% and 3.5 µm have been measured in the materials that make up the stack with cutting speeds higher than 140 m/min and feed rates between 200 and 250 mm/min. However, the greatest adhesive losses occur at high cutting speeds.

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“…As part of this subject, the two research papers were published. Uddin et al [12] applied a multi-dimensional evaluation of hole quality in an Al6061 alloy after drilling. Authors have employed the novel octagonal-ellipse load cell set-up for measurements of feed force and torque.…”

Section: Ofmentioning

confidence: 99%

Advances in Hard–to–Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity

2020

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The rapid growth of a modern industry results in a growing demand for construction materials with excellent operational properties. However, the improved features of these materials can significantly hinder their manufacturing, therefore they can be defined as hard–to–cut. The main difficulties during the manufacturing/processing of hard–to–cut materials are attributed to their high hardness and abrasion resistance, high strength at room or elevated temperatures, increased thermal conductivity, as well as their resistance to oxidation and corrosion. Nowadays the group of hard–to–cut materials includes the metallic materials, composites, as well as ceramics. This special issue, “Advances in Hard–to–Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity” provides a collection of research papers regarding the various problems correlated with hard–to–cut materials. The analysis of these studies reveals primary directions regarding the developments in manufacturing methods, and the characterization and optimization of hard–to–cut materials.

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Evaluating Hole Quality in Drilling of Al 6061 Alloys

Cited by 87 publications

References 27 publications

Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach

Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach

One-Shot Drilling Analysis of Stack CFRP/UNS A92024 Bonding by Adhesive

Advances in Hard–to–Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity

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