Evaluation of novel tool geometries in dry drilling aluminium 2024-T351/titanium Ti6Al4V stack

Zhu, Zhaoju; Guo, Kai; Sun, Jie; Li, Jianfeng; Liu, Yang; Zheng, Yihao; Chen, Lei

doi:10.1016/j.jmatprotec.2018.04.044

Cited by 70 publications

(27 citation statements)

References 22 publications

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“…This shows that at lower drilling parameters, multi-spindle drilling using a poly-drill head gives better SR. Lower CS and FR are also recommended by Giasin et al [31], as higher CS might cause more vibration and chatter, which reduces the surface quality. Furthermore, a higher FR increases the chip thickness, which might also result in a higher SR of holes [32]. As mentioned earlier, all the drilling tools used in this study have a 6 mm diameter.…”

Section: Optimization Of Drilling Conditions Using Taguchi Analysismentioning

confidence: 89%

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: 89%

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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“…It was decided to measure the height of the exit interlayer burr, i.e. the burr on the bottom surface of the top layer, which is believed to be the main contributor to the overall interlayer burr formation in stack drilling [5]. For each hole, two line scans using a contactless profilometer (Nanofocus μm scan) were carried out across the centre of the hole, at 0 • and 90 • , thereby gathering data representing the borehole edges in four locations (0 • , 90 • , 180 • and 270 • ).…”

Section: Burr Height Measurementmentioning

confidence: 99%

“…Various studies have focused on the reduction of interlayer burr formation through the optimisation of process parameters in drilling of aerospace stacks. Zhu et al [5] investigated the impact of tool geometry on burr formation in dry drilling of aluminium-titanium stacks. They observed that double cone drills produce significantly smaller burrs when compared with drills with multipoint and step geometries.…”

Section: Introductionmentioning

confidence: 99%

The effect of interlayer gap width on burr formation in drilling of aluminium-aluminium aerospace stacks

Pardo

Cseke

Heinemann

et al. 2019

Int J Adv Manuf Technol

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Interlayer burr formation during drilling of stacks is a widespread issue in the aerospace industry. The minimisation of the interlayer burr would contribute to significant time and cost savings, as it would allow for clamping, drilling and fastening to be carried out without any intermediate deburring that requires separating the layers. This paper reports about a notbefore observed phenomenon associated with the relationship between interlayer gap width and burr height when drilling aluminium-aluminium stacks with the presence of sealant at the interface. Initial experiments of the research were conducted to determine the interlayer gap widths in relation to a range of clamping forces, followed by drilling experiments to assess how the interlayer gap width affects the interlayer burr formation process and burr height. Although the presence of an interlayer gap results in larger burrs being formed, it allows upwards-travelling chips to enter the gap and erode away the newly formed burr. Larger interlayer gap widths were found to yield a more pronounced abrasion of the interlayer burrs, often leading to their complete removal; in some cases, this abrasion even resulted in a noticeable rounding of the borehole edges. This phenomenon was found to strongly affect the interlayer borehole quality and, thus, makes this research highly significant to the aerospace industry, where the quality of the borehole at the stack interface is of major interest.

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“…This is likely due to the different mechanism of burr formation at the entry and exit sides of the holes. According to Zhu et al [52], the tearing occurs as a bending action followed by clean shearing or lateral extrusion causing entrance burrs while exit Analysis of the Performance of Drilling Operations for Improving Productivity DOI: http://dx.doi.org/10.5772/intechopen.96497 burrs formed as a result of plastic deformation of the materials. Besides this, low temperature and thrust force are the reasons for small burrs on the entry side of the hole which can be removed by chamfering [53].…”

Section: Quality Assessment Of Drilled Holes In Multi-spindle Drillinmentioning

confidence: 99%

Analysis of the Performance of Drilling Operations for Improving Productivity

Tolouei‐Rad¹,

Aamir²

2021

Drilling Technology

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Drilling is a vital machining process for many industries. Automotive and aerospace industries are among those industries which produce millions of holes where productivity, quality, and precision of drilled holes plays a vital role in their success. Therefore, a proper selection of machine tools and equipment, cutting tools and parameters is detrimental in achieving the required dimensional accuracy and surface roughness. This subsequently helps industries achieving success and improving the service life of their products. This chapter provides an introduction to the drilling process in manufacturing industries which helps improve the quality and productivity of drilling operations on metallic materials. It explains the advantages of using multi-spindle heads to improve the productivity and quality of drilled holes. An analysis of the holes produced by a multi-spindle head on aluminum alloys Al2024, Al6061, and Al5083 is presented in comparison to traditional single shot drilling. Also the effects of using uncoated carbide and high speed steel tools for producing high-quality holes in the formation of built-up edges and burrs are investigated and discussed.

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Evaluation of novel tool geometries in dry drilling aluminium 2024-T351/titanium Ti6Al4V stack

Cited by 70 publications

References 22 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

The effect of interlayer gap width on burr formation in drilling of aluminium-aluminium aerospace stacks

Analysis of the Performance of Drilling Operations for Improving Productivity

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