Experimental investigation to optimize tool performance in high-speed drilling: a comparative study

Prasad, Balla Srinivasa; Kiran, D. S. Sai Ravi

doi:10.1007/s40430-019-2049-4

Cited by 8 publications

(3 citation statements)

References 17 publications

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“…This will cause in softening of the work material. As the time of temperature increases which will result in Expansion or contraction of a structure at the stage stress will be increased [13].…”

Section: Figurementioning

confidence: 99%

3D Finite Element Modeling and Simulation of Friction Drilling Process

Srilatha¹,

Prasad²,

Anipey³

2019

IJEAT

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 Abstract: Friction drilling is an advanced drilling process in which that can be utilize the heat produced between the workpiece and rotating drilling tool bit to soften the work material and producing a hole on it. In this investigation our interest is to choose work material is Al 7075-T351 to analyze the stress, strain, temperature and work material deformation in friction drilling. Al 7075-T351 square-tube materials were drilled on a computer numerical control (CNC) machine centre by friction drilling has analyzed at different rotational speed and feed rate through controlled operation tests. The temperatures in work piece and tool were more in Friction drilling. Simulation has required perceiving the material flow, stresses, temperatures, and strains. Those are tough to quantify experimentally through friction drilling. In this study, CATIA is used to design the tool model and the software which is used to simulate the performance of friction drilling is DEFORM-3D and effect of tool material speed and feed rate on shape of bushing formed is observed. Taguchi's technique L9 OrthogonalArray was used to analyze the optimum values. Signal to noise ratios also administered for optimization of parameters.

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Section: Figurementioning

confidence: 99%

3D Finite Element Modeling and Simulation of Friction Drilling Process

Srilatha¹,

Prasad²,

Anipey³

2019

IJEAT

Self Cite

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“…The key factors that affect drill tool life are relative vibrations between the tool and the workpiece, chemical reactions, chip formation and evacuation and process temperature [7,8]. However, the most important aspects are the machining parameters such as feed rate (f) and cutting speed (Vc) [9].…”

Section: Introductionmentioning

confidence: 99%

Influence of Variation of Cutting Speed on Wear, Cutting Forces and Tool Temperature during Performance Drilling

et al. 2023

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The paper presents the results and the influence a single factor has in the drilling process. The research is focused on how modifying the cutting speed influences parameters like cutting forces, cutting temperature, tool life, wear mechanism, and chip formation. For this experiment three different cutting speeds have been tested on high-speed adapted twisted drill geometry, each of them corresponding to a certain cutting domain: 200 m/min, 165 m/min and 110 m/min. The temperature, predicted with finite element simulation (FEM), forces, wear evolution and the shape of chips have been analysed in order to prove if high speed adapted drill geometry can be used instead of an ordinary drill while performing at lower speeds. The tests certified the ability of a drill designed for high speed to process in conditions associated with lower cutting speeds, behaving similarly in all the cases.

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“…However, it could not eliminate SDR completely because only the feed movement was controlled. Prasad and Sai Ravi Kiran (2019) developed a method that controlled the rotation and drilling speeds of the drill rod using a mathematical algorithm, which decreased drilling accidents to some extent. Liu et al (2023) established a dynamic simulation model of sticking system using an advanced modeling environment for performing simulation of engineering systems and analyzed the pressure characteristic curves during the actual sticking process.…”

Section: Introductionmentioning

confidence: 99%

PID and compliance control-based anti-sticking of drill rod in underground mining

Li,

Zhu,

Xia

et al. 2023

RIA

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Purpose During drilling in coal mines, sticking of drill rod (referred to as SDR in this work) is a potential threat to underground safety. However, no practical measures to deter SDR have been developed yet. The purpose of this study is to develop an anti-SDR strategy using proportional-integral-derivative (PID) and compliance control (PIDC). The proposed strategy is compatible with the drilling process currently used in underground coal mines using drill rigs. Therefore, this study aims to contribute to the PIDC strategy for solving SDR. Design/methodology/approach A hydraulic circuit to reduce SDR was built based on a load-independent flow distribution system, a PID controller was designed to control the inlet hydraulic pressure of the rotation motor and a typical compliance control approach was adopted to control the feed force and displacement. Moreover, the weight and optimal combination of the alternative admittance control parameters for the feed cylinder were obtained by adopting the orthogonal experiment approach. Furthermore, a fuzzy admittance control approach was proposed to control the feed displacement. Experiments were conducted to test the effectiveness of the proposed method. Findings The experimental results indicated that the PIDC strategy was appropriate and effective for controlling the rotation motor and feed cylinder; thus, the proposed method significantly reduces the SDR during drilling operations in underground coal mines. Research limitations/implications As the PIDC strategy solves the SDR problem in underground coal mines, it greatly improves the safety of coal mine operation and decreases the power cost. Consequently, it brings the considerable benefits of coal mine production and vast application prospects in other corresponding fields. Actual drilling conditions are difficult to accurately simulate in a laboratory; thus, for future work, drilling experiments can be conducted in actual underground coal mines. Originality/value The PIDC-based anti-SDR strategy proposed in this study satisfactorily controls the rotation motor and feed cylinder and facilitates the feed and rotation movements. Furthermore, the tangible novelty of this study results is that it improves the frequency response of the entire drilling system. The drilling process with PIDC decreased the occurrence of SDR by 50%; therefore, the anti-SDR strategy can significantly improve the safety and efficiency of underground coal mining.

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Experimental investigation to optimize tool performance in high-speed drilling: a comparative study

Cited by 8 publications

References 17 publications

3D Finite Element Modeling and Simulation of Friction Drilling Process

3D Finite Element Modeling and Simulation of Friction Drilling Process

Influence of Variation of Cutting Speed on Wear, Cutting Forces and Tool Temperature during Performance Drilling

PID and compliance control-based anti-sticking of drill rod in underground mining

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