Experimental Study of Drilling Temperature, Geometrical Errors and Thermal Expansion of Drill on Hole Accuracy When Drilling CFRP/Ti Alloy Stacks

Kolesnyk, Vitalii; Peterka, Jozef; Kuruc, Marcel; Šimna, Vladimír; Moravčíková, Jana; Vopát, Tomáš; Lisovenko, Dmytro

doi:10.3390/ma13143232

Cited by 28 publications

(33 citation statements)

References 52 publications

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“…The quality of the drilled holes is mainly determined by the sum of the errors that occur during the drilling process such as tool tolerance and coaxiality, the imbalance of cutting forces, deviation of the hole perpendicularity, vibration, spindle clearance, thermal expansion of the tool and workpiece or the effect of outgoing chips on the hole wall. [ 35 ]. Another very important factor is the thermal expansion of the tool and workpiece material [ 12 , 35 ].…”

Section: Resultsmentioning

confidence: 99%

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Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel

et al. 2021

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Dry machining is one of the main ways to reduce the environmental burden of the machining process and reduce the negative effect of the cutting fluid and aerosols on operators. In addition, dry machining can reduce overall machining costs and, in the case of large workpieces, reduce the extra work associated with removing residual cutting fluid from the workpiece and adjacent area. For high-strength structural steel products, it is typical to drill holes with larger diameters of around 20 mm. Therefore, this work is devoted to the investigation of the dry drilling process carried out on a workpiece made of S960QL steel with a helical drill with a diameter of 21 mm. The aim was to find suitable cutting conditions for dry drilling with regard to process stability and workpiece quality. An experiment performed with a coolant served as a comparison base. A dry drilling experiment was performed with cutting speeds from 30 to 70 m·min−1 and feeds from 0.1 to 0.3 mm·rev−1, and with the results of this experiment, the same experiment with flood cooling was performed. During the drilling process, spindle torque values were recorded using the indirect spindle current recording method. The macroscopic chip morphology was studied to understand the cutting process. The chip thickness ratio was measured, as well as the maximum diameter of spiral chips. On the final workpiece, the qualitative and dimensional parameters of the holes were evaluated, such as the diameter, cylindricity and surface roughness, depending on the change in the cutting conditions and cutting environment. Evaluation of the obtained data led to the following conclusions. When drilling the S960QL material, there is only a very small increase in the drilling torque during dry drilling compared to drilling with cutting fluid. The increase in friction demonstrated by the chip thickness coefficient is significant. The influence of the environment on the dimensional accuracy showed a tendency for a slight increase in the holes’ diameters during dry machining. In comparison, the cylindricity of the dry-drilled holes shows a lower deviation than the holes drilled with cutting fluid. The surface roughness of the holes after dry drilling is affected by the increased friction of the outgoing chips, despite the resulting parameters being very good due to the drilling technology standards. This work provides a comprehensive view of the dry drilling process under defined conditions, and the results represent suitable cutting conditions to achieve a stable cutting process and a suitable quality of drilled holes.

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Section: Resultsmentioning

confidence: 99%

“…[ 35 ]. Another very important factor is the thermal expansion of the tool and workpiece material [ 12 , 35 ]. The most common cause of a hole shape error is dynamic deflections of the drill due to unbalanced forces [ 11 ].…”

Section: Resultsmentioning

confidence: 99%

Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel

et al. 2021

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“…Hardening is carried out to dissolve a significant part of carbides and obtain high-alloy martensite. Therefore, tempering temperatures are elevated and are limited only by the need to maintain fine grain and sufficient viscosity [9][10][11].…”

Section: Literature Reviewmentioning

confidence: 99%

Carbonitration of a Tool for Pressing Stainless Steel Pipes

Иванов

Mohylenets²,

Dumenko³

et al. 2020

JES

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To upgrade the operational stability of the tool at LLC “Karbaz”, Sumy, Ukraine, carbonation of tools and samples for research in melts of salts of cyanates and carbonates of alkali metals at 570–580 °C was carried out to obtain a layer thickness of 0.15–0.25 mm and a hardness of 1000–1150 НV. Tests of the tool in real operating conditions were carried out at the press station at LLC “VO Oscar”, Dnipro, Ukraine. The purpose of the test is to evaluate the feasibility of carbonitriding of thermo-strengthened matrix rings and needle-mandrels to improve their stability, hardness, heat resistance, and endurance. If the stability of matrix rings after conventional heat setting varies around 4–6 presses, the rings additionally subjected to chemical-thermal treatment (carbonitration) demonstrated the stability of 7–9 presses due to higher hardness, heat resistance, the formation of a special structure on the surface due to carbonitration in salt melts cyanates and carbonates. Nitrogen and carbon present in the carbonitrided layer slowed down the processes of transformation of solid solutions and coagulation of carbonitride phases. The high hardness of the carbonitrified layer is maintained up to temperatures above 650 °C. If the stability of the needle-mandrels after conventional heat treatment varies between 50–80 presses, the needles, additionally subjected to chemical-thermal treatment (carbonitration) showed the stability of 100–130 presses due to higher hardness, wear resistance, heat resistance, the formation of a special surface structure due to carbonitration in melts of salts of cyanates and carbonates. Keywords: needle-mandrel, matrix ring, pressing, heat treatment, carbonitration.

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“…Carbon-fiber-reinforced plastic (CFRP) can be used as an excellent lightweight replacement for steel in mechanical industries [ 1 , 2 , 3 , 4 , 5 ] due to its outstanding specific strength characteristics [ 6 , 7 , 8 , 9 , 10 , 11 ], as well as its sound damping characteristics [ 12 , 13 , 14 , 15 , 16 , 17 ]. The dynamic response of a CFRP structure varies with the changes in structural stiffness with respect to the direction of the carbon fiber; hence, CFRP is anisotropic in nature due to the different orientations of the carbon fiber [ 18 , 19 , 20 , 21 , 22 , 23 , 24 ]. In addition, there are several weaving processes for producing CFRP products, such as plain-weave, twill-weave, and unidirectional-weave, to create a three-dimensional structure; sometimes, a combination of different weaving methods is utilized [ 20 , 21 , 22 , 23 , 24 ].…”

Section: Introductionmentioning

confidence: 99%

“…The dynamic response of a CFRP structure varies with the changes in structural stiffness with respect to the direction of the carbon fiber; hence, CFRP is anisotropic in nature due to the different orientations of the carbon fiber [ 18 , 19 , 20 , 21 , 22 , 23 , 24 ]. In addition, there are several weaving processes for producing CFRP products, such as plain-weave, twill-weave, and unidirectional-weave, to create a three-dimensional structure; sometimes, a combination of different weaving methods is utilized [ 20 , 21 , 22 , 23 , 24 ]. Therefore, compared to isotropic materials such as steel, the industrial utilization of CFRP is challenging due to its anisotropic property arising from the weaving method and the direction of the carbon fiber.…”

Section: Introductionmentioning

confidence: 99%

Temperature-Dependent Dynamic Characteristics of Carbon-Fiber-Reinforced Plastic for Different Spectral Loading Patterns

Kim¹

2020

Materials

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The dynamic properties of carbon-fiber-reinforced plastic (CFRP) can be efficiently estimated through a modal damping coefficient and a resonance frequency, and the modal parameters can be calculated using a frequency response function (FRF). The modal parameters used in an CFRP FRF are influenced by the carbon fiber direction, temperature, and spectral loading pattern, as well as the operating conditions. In this study, three parameters—temperature, spectral loading pattern, and carbon fiber direction—were selected as the influential factors for CFRP dynamics, and the sensitivity index formulation was derived from the parameter-dependent FRF of the CFRP structure. The derivatives of the parameter-dependent FRF over the three considered parameters were calculated from the measured modal parameters, and the dynamic sensitivity of the CFRP specimens was explored from the sensitivity index results for five different directional CFRP specimens. The acceleration response of a simple CFRP specimen was obtained via a uniaxial excitation test at temperatures ranging from −8 to 105 °C for the following two spectral loading cases: harmonic and random.

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Experimental Study of Drilling Temperature, Geometrical Errors and Thermal Expansion of Drill on Hole Accuracy When Drilling CFRP/Ti Alloy Stacks

Cited by 28 publications

References 52 publications

Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel

Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel

Carbonitration of a Tool for Pressing Stainless Steel Pipes

Temperature-Dependent Dynamic Characteristics of Carbon-Fiber-Reinforced Plastic for Different Spectral Loading Patterns

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