Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

Ghasemi, Arman; Khorasani, Amir Mahyar; Gibson, Ian

doi:10.3390/ma11010140

Cited by 27 publications

(21 citation statements)

References 45 publications

(56 reference statements)

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“…It is therefore apparent that the relationships between the drilling parameters and the thrust force, tool wear, and burr formation may vary with the underlying workpiece and drill-bit material. In other words, while the process mechanics, i.e., material removal and chip generation, seems to be generic, the process outcome can still change with the effective parameters and conditions employed [21]. This warrants further investigation to explore and validate such perspective in drilling.…”

Section: Introductionmentioning

confidence: 99%

Evaluating Hole Quality in Drilling of Al 6061 Alloys

et al. 2018

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Hole quality in drilling is considered a precursor for reliable and secure component assembly, ensuring product integrity and functioning service life. This paper aims to evaluate the influence of the key process parameters on drilling performance. A series of drilling tests with new TiN-coated high speed steel (HSS) bits are performed, while thrust force and torque are measured with the aid of an in-house built force dynamometer. The effect of process mechanics on hole quality, e.g., dimensional accuracy, burr formation, surface finish, is evaluated in relation to drill-bit wear and chip formation mechanism. Experimental results indicate that the feedrate which dictates the uncut chip thickness and material removal rate is the most dominant factor, significantly impacting force and hole quality. For a given spindle speed range, maximum increase of axial force and torque is 44.94% and 47.65%, respectively, when feedrate increases from 0.04 mm/rev to 0.08 mm/rev. Stable, jerk-free cutting at feedrate of as low as 0.04 mm/rev is shown to result in hole dimensional error of less than 2%. A low feedrate along with high spindle speed may be preferred. The underlying tool wear mechanism and progression needs to be taken into account when drilling a large number of holes. The findings of the paper clearly signify the importance and choice of drilling parameters and provide guidelines for manufacturing industries to enhance a part’s dimensional integrity and productivity.

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Section: Introductionmentioning

confidence: 99%

Evaluating Hole Quality in Drilling of Al 6061 Alloys

et al. 2018

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“…The advantage of GMDH algorithm over the other training algorithms lies in the fact that it can self‐adapt its topology and self‐select its number of input variables based on a predefined fitness function and available set of data. As a result, this algorithm which is proposed by Ivanchenko is preferred in many publications around the world including in the field of machining …”

Section: Methods Usedmentioning

confidence: 99%

Optimization of material removal rate in wire EDM by polynomial neural network models

Dutta

Majumder

Panja

2019

Computational Intelligence

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Maximization of material removal rate may yield impractical results if the cost for generation of removal rate is not included in the optimization. Presently, there are many studies which have applied different linear, nonlinear, and metaheuristics optimization techniques to maximize material removal rate but none of the approaches have the capability of self‐adaptation. In none of these studies impact of cost on removal rate was considered. That is why, in the present study, the Group Method of Data Handling which is a technique to develop polynomial neural network (PNN) models was utilized for the first time to maximize material removal rate with the help of the on‐ and off‐stage current as the design variables constrained by the operating costs. The PNN architecture is widely used in many fields of technology and science. However, application of this architecture is scarce in case of optimization of material removal rate. According to the results the accuracy level and time of convergence in case of PNN was found to be better compared to that from artificial neural network and linear models both of which were utilized for estimation of the output variable.

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“…Apart from that, geopolymer utilizes waste materials such as recycled concrete and unwanted fly ash. This material has interesting properties because it is very durable and stable at high temperature; thus, this property has been one of the reasons why geopolymer materials are now widely used in many sectors, especially in the engineering sector such as civil construction, automotive industry, and aviation sector [ 2 , 3 , 4 , 5 ].…”

Section: Introductionmentioning

confidence: 99%

Tool Wear and Surface Evaluation in Drilling Fly Ash Geopolymer Using HSS, HSS-Co, and HSS-TiN Cutting Tools

et al. 2021

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This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications.

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Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

Cited by 27 publications

References 45 publications

Evaluating Hole Quality in Drilling of Al 6061 Alloys

Evaluating Hole Quality in Drilling of Al 6061 Alloys

Optimization of material removal rate in wire EDM by polynomial neural network models

Tool Wear and Surface Evaluation in Drilling Fly Ash Geopolymer Using HSS, HSS-Co, and HSS-TiN Cutting Tools

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