Hole Making Using Ball Helical Milling on Titanium Alloys

Olvera, D.; Lacalle, Luís Norberto López de; Urbikaín, Gorka; Lamíkiz, Aitzol; Rodal, P.; Zamakona, I.

doi:10.1080/10910344.2012.673958

Cited by 71 publications

(39 citation statements)

References 19 publications

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“…The study also suggested that the hole quality should be evaluated by measuring geometry accuracy (hole diameter and roundness error), burr formation, and surface roughness. Olvera et al [12] showed that ball helical milling was able to produce holes in titanium alloy with an average surface roughness of 0.6 μm, compared with 1 μm for conventional drilling. However, this study also found that ball helical milling caused a greater reduction in microhardness: an average drop of 13 HRC was observed for helical milling compared to a drop of only 6 HRC for drilling.…”

Section: Introductionmentioning

confidence: 99%

Hole-making processes and their impacts on the microstructure and fatigue response of aircraft alloys

Sun

Lemoine

Doyle

et al. 2016

Int J Adv Manuf Technol

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A comparative study on conventional drilling and helical milling has been reported under the context of aircraft alloy hole making. The impacts of these two different machining processes on the microstructures and the fatigue performance of different aircraft alloys have been elaborated. Results show that both alloys undergo more severe surface/subsurface plastic deformation under conventional drilling comparing to helical milling process. Helical milling leads to a longer coupon fatigue life compared to conventional drilling for both alloys. The fatigue life of Al 2024-T3 is significantly longer than that of Ti-6Al-4V under all machining conditions. The use of coolant generally produces less damaged surface and leads to enhanced fatigue performance of the machined alloys. In addition, the machined surface roughness has been studied to further elaborate the effects of different machining processes.

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Section: Introductionmentioning

confidence: 99%

Hole-making processes and their impacts on the microstructure and fatigue response of aircraft alloys

Sun

Lemoine

Doyle

et al. 2016

Int J Adv Manuf Technol

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“…In carbon fiber reinforced plastic (CFRP), low delamination levels are obtained through hole-making with helical milling technique [14]. Through helical milling it is possible to obtain finished boreholes in just one operation, avoiding reaming operations [15]. Due to these advantages, helical milling has been consolidating as a sustainable hole-making process.…”

mentioning

confidence: 99%

“…In helical milling and other hole-making processes, usually the quality in the borehole end is poorer than in the beginning. It may be related to the high tool-workpiece contact area increasing tool deflection and radial force [14], resulting in dimensional, geometrical and microgeometrical variation [15,42]. Furthermore, in helical milling the tool realizes more orbital revolutions in the beginning than in the end of the borehole, resulting in the smoothing of the surface due to the peripheral cut.…”

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confidence: 99%

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Pereira

Silva

Lauro

et al. 2019

Applied Soft Computing

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Helical milling is a hole-making process which has been applied in hardened materials. Due to the difficulties on achieving high-quality boreholes in these materials, the influence of noise factors, and multi-quality performance outcomes, this work aims the multi-objective robust design of hole quality on AISI H13 hardened steel. Experiments were carried out through a central composite design considering process and noise factors. The process factors were the axial and tangential feed per tooth of the helix, and the cutting velocity. The noise factors considered were the tool overhang length, the material hardness and the borehole height of measurement. Response models were obtained through response surface methodology for roughness and roundness outcomes. The models presented good explanation of data variability and good prediction capability. Mean and variance models were derived through robust parameter design for all responses. Similarity analysis through cluster analysis was realised, and average surface roughness and total roundness were selected to multi-objective optimisation. Mean square error optimisation was performed to achieve bias and variance minimization. Multi-objective optimisation through normalized normal constraint was performed to achieve a robust Pareto set for the hole quality outcomes. The normalized normal constraint optimisation results outperformed the results of other methods in terms of evenness of the Pareto solutions and number of Pareto optimal solutions. The most compromise solution was selected considering the lowest Euclidian distance to the utopia point in the normalized space. Individual and moving range control charts were used to confirm the robustness achievement with regard to noise factors in the most compromise Pareto optimal solution. The methodology applied for robust modelling and optimisation of helical milling of AISI H13 hardened steel was confirmed and may be applied to other manufacturing processes. KeywordsHelical milling; AISI H13 hardened steel; Multi-objective robust optimization; Robust parameter design; Normalized normal constraint method. R 2 coefficient of determinationRadj 2 adjusted coefficient of determination Radj 2 prediction coefficient of determination

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“…Among 30 holes drilled for each cutting speed, the actual diameters of hole numbers 1,8,15,23, and 30 are recorded and Eh (%) is computed. The scatter plot of calculated Eh (%) is shown in Figure 8.…”

Section: Hole Diameter Assessmentmentioning

confidence: 99%

“…Different machining operations are performed on CFRP workpieces-such as milling and water-jet cutting-but drilling stands out as the most frequently used approach [6]. In addition to drilling, helical milling can also be used for making holes in structural components [7,8]. However, significant cutting resistance, which is detrimental to the quality of machined parts, is generated due to the CFRP's inhomogeneous and anisotropic characteristics, low thermal conductivity, and high tensile and fatigue strength [9].…”

Section: Introductionmentioning

confidence: 99%

Assessment of Cutting Performance of Cemented Tungsten Carbide Drills in Drilling Multidirectional T700 CFRP Plate

Ali

Yue

et al. 2018

JMMP

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Abstract:The drilling of carbon fiber reinforced polymer (CFRP) plate is very critical in its structural applications in aeronautical, aerospace, and automobile industries. For ensuring the good quality of drilled holes in terms of least drilling damage and prolonged tool life, suitable selection of drill geometry and material, and drilling parameters-such as cutting speed and feed rate-are imperative in the drilling of CFRP plate. This study aims to evaluate the cutting performance of conventional two-flute twist drills made of cemented tungsten carbide YG6X (WC-6 wt % Co) for the dry drilling of the multidirectional T700 CFRP plate. The effects of varying cutting speed and tool wear pattern on the drilling performance are analyzed. The drilling performance is assessed in terms of hole quality by the qualitative and quantitative analysis of drilling-induced delamination and hole diameter. Furthermore, the correlation between the tool wear progression and the drilled hole quality is established. Through this assessment, a suitable set of drilling parameters, i.e., cutting speed of 9000 rpm and feed rate of 400 mm/min, is proposed for producing the best quality holes for multidirectional T700 CFRP plate.

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Hole Making Using Ball Helical Milling on Titanium Alloys

Cited by 71 publications

References 19 publications

Hole-making processes and their impacts on the microstructure and fatigue response of aircraft alloys

Hole-making processes and their impacts on the microstructure and fatigue response of aircraft alloys

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Assessment of Cutting Performance of Cemented Tungsten Carbide Drills in Drilling Multidirectional T700 CFRP Plate

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