New Strategies For Hole Making In Ti-6Al-4V

Urbicain, G.; Olvera, D.; Lacalle, Luis Norberto López de; Zamakona, I.; Rodal, P.; Segui, Vicente Jesus

doi:10.1063/1.3273651

Cited by 6 publications

(5 citation statements)

References 10 publications

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“…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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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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“…Urbicain et al 5 concluded that surface roughness values in helical milling are less than conventional drilling by examining different methods of producing holes Also, by measuring the diametrical error of the hole in the two sections, they concluded that the holes created by the helical milling method have fewer errors than the conventional drilling method. Generally, the diametrical error represents the deviation of the formed hole diameter from the desired diameter.…”

Section: Introductionmentioning

confidence: 99%

Dynamic modeling and experimental investigation of hole making accuracy in the helical milling process

Paysarvi

Abootorabi

Jalili

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Helical milling is one of the novel hole-making methods to create a hole with high accuracy and quality. In this study, the helical milling process is dynamically modeled using a set of second-order differential equations. In this modeling, the tool is considered a cantilever beam with a degree of freedom in all three directions of x, y, and z. Experimental tests were conducted to investigate the validity of the obtained theoretical relations and the effects of different parameters such as material, diameter, and rotational speed of the cutting tool on the precision of the created hole. The error of the theoretical relations in predicting the hole diameter is 2.7%, indicating the high precision of the accomplished modeling. Theoretical relations show that the error of the chip removal path decreases by increasing each of the parameters, namely, tool stiffness, the rotational speed of the tool, tool diameter, and tangential feed per tooth. In contrast, the error of the chip removal path increases by increasing each of the parameters, namely, the speed of the tool in the helical path and axial feed per tooth. It has been shown that improving the cutting tool material in terms of strength or increasing the rotational speed of the tool and the cutting tool diameter causes a reduction in the diametrical error. It has been shown that the diametrical error rate is 0.9% with the change of the cutting tool from HSS-E to carbide, and it has reduced to 0.6% by increasing the rotational speed of the tool from 900 r/min to 2100 r/min.

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“…In addition, it is found that helical milling produces compressive residual stresses [15]. G. Urbicain compares conventional drilling with two other strategies (helical milling and contouring milling), obtaining greater diameter accuracy, less angular deviation and burr-free deviation in helical milling [16]. E. Brinksmeier [17] performs a mathematical decomposition of the movement carried out to facilitate its study, relating the material that is milled and the material drilled during an operation according to two independent parameters (hole and tool diameter), and defining a new "G" parameter, as the quotient between milled material and drilled, deducing that this ratio is independent of the axial velocity, as verified in Equation (1):…”

Section: Introductionmentioning

confidence: 99%

Study of the Influence of Helical Milling Parameters on the Quality of Holes in the UNS R56400 Alloy

2020

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Helical milling has been positioned as an alternative to conventional drilling, where the advantages it offers make it very attractive for use on difficult-to-machine alloys such as the titanium alloy UNS R56400. However, the correlation between the indicator of hole quality and the kinematic parameters has rarely been studied. The kinematics are what bring most advantages and that is why it is necessary to know their influence. In this aspect, there are different focuses of problems associated with the complexity of the process kinematics, which makes it necessary to undertake a deeper analysis of the process and to carry out a preliminary study. To address this problem, a DOE (Design of Experiments) is proposed to identify the sensitivity and the main trends of the properties that define the quality holes with respect to the kinematic parameters. At the same time, a nomenclature is proposed to unify and avoid misinterpretations. This study has allowed us to obtain conclusive results that offer very relevant information for future research

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New Strategies For Hole Making In Ti-6Al-4V

Cited by 6 publications

References 10 publications

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

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

Dynamic modeling and experimental investigation of hole making accuracy in the helical milling process

Study of the Influence of Helical Milling Parameters on the Quality of Holes in the UNS R56400 Alloy

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