Formation of interlayer gap and control of interlayer burr in dry drilling of stacked aluminum alloy plates

Tian, Wei; Hu, Jian; Liao, Wenhe; Yin, Bo; Zhang, Lin

doi:10.1016/j.cja.2015.11.002

Cited by 35 publications

(19 citation statements)

References 23 publications

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“…They observed that double cone drills produce significantly smaller burrs when compared with drills with multipoint and step geometries. Melkote et al [6] and Tian et al [7] established relationships between feed rate and burr height and thickness, which is explained by the strong correlation between feed rate and thrust force [8]. The interlayer gap width is believed to strongly influence interlayer burr formation and has thus been the subject of extensive research.…”

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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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

View full text Add to dashboard Cite

show abstract

“…During the drilling process, the interlayer gap has a positive correlation with the interlayer burr size, and the largest interlayer gap occurs at the drilling center [12]. It is obvious that the interlayer gap decreases as the clamping force increases until the two plates are entirely in contact with each other.…”

Section: Modeling Of the Interlayer Gap With Bidirectional Clamping Fmentioning

confidence: 99%

“…Many investigations have been conducted on the burr formation and elimination in drilling metal materials. Researchers indicate that the process parameters, workpiece parameters and tool parameters are the most significant influencing factors of burr formation [12][13][14]. Abdelhafeez et al [15] conducted fatigue tests on as-drilled and duburred specimens made of titanium and aluminium alloys and they found that the deburring dramatically increased the fatigue performance of the Ti-6Al-4V and AA7010 samples.…”

Section: Introductionmentioning

confidence: 99%

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Modeling and Optimization of Bidirectional Clamping Forces in Drilling of Stacked Aluminum Alloy Plates

et al. 2020

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Interlayer burrs formation during drilling of stacked plates is a common problem in the field of aircraft assembly. Burrs elimination requires extra deburring operations which is time-consuming and costly. An effective way to inhibit interlayer burrs is to reduce the interlayer gap by preloading clamping force. In this paper, based on the theory of plates and shells, a mathematical model of interlayer gap with bidirectional clamping forces was established. The relationship between the upper and lower clamping forces was investigated when the interlayer gap reaches zero. The optimization of the bidirectional clamping forces was performed to reduce the degree and non-uniformity of the deflections of the stacked plates. Then, the finite element simulation was conducted to verify the mathematical model. Finally, drilling experiments were carried out on 2024-T3 aluminum alloy stacked plates based on the dual-machine-based automatic drilling and riveting system. The experimental results show that the optimized bidirectional clamping forces can significantly reduce the burr heights. The work in this paper enables us to understand the effect of bidirectional clamping forces on the interlayer gap and paves the way for the practical application.

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“…Burrs may occur at the entrance and/or at the exit of the hole as a consequence of uncut material which is plastically deformed [7]. …”

Section: Introductionmentioning

confidence: 99%

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

et al. 2016

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Composite materials are widely employed in the naval, aerospace and transportation industries owing to the combination of being lightweight and having a high modulus of elasticity, strength and stiffness. Drilling is an operation generally used in composite materials to assemble the final product. Damages such as the burr at the drill entrance and exit, geometric deviations and delamination are typically found in composites subjected to drilling. Drills with special geometries and pilot holes are alternatives used to improve hole quality as well as to increase tool life. The present study is focused on the drilling of a sandwich composite material (two external aluminum plates bound to a polyethylene core). In order to minimize thrust force and burr height, the influence of drill geometry, the pilot hole and the cutting parameters was assessed. Thrust force and burr height values were collected and used to perform an analysis of variance. The results indicated that the tool and the cutting speed were the parameters with more weight on the thrust force and for burr height they were the tool and the interaction between tool and feed. The results indicated that drilling with a pilot hole of Ø4 mm exhibited the best performance with regard to thrust force but facilitated plastic deformation, thus leading to the elevation of burr height, while the lowest burr height was obtained using the Brad and Spur drill geometry.

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Formation of interlayer gap and control of interlayer burr in dry drilling of stacked aluminum alloy plates

Cited by 35 publications

References 23 publications

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

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

Modeling and Optimization of Bidirectional Clamping Forces in Drilling of Stacked Aluminum Alloy Plates

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

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