Numerical modeling and experimental analysis of thrust cutting force and torque in drilling process of titanium alloy Ti6Al4V

Glaa, Nawel; Mehdi, Kamel; Zitoune, Rédouane

doi:10.1007/s00170-018-1758-7

Cited by 30 publications

(16 citation statements)

References 16 publications

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“…In drilling of the fiber-reinforced plastic, Wei et al [10] reported that the thrust force and hole quality are strongly influenced by the feedrate while the effect of the cutting speed is relatively less. In drilling of Ti6Al4V, Glaa et al [11] proposed and studied a numerical model in estimating force and torque by taking regenerative chatter and process damping into account, and evaluated the effect of process parameters.…”

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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“…Therefore, it is difficult to drill titanium alloys because rapid tool wear occurs at the cutting edges of tool. 11,12 To overcome such type of problems, the use of laser may be a suitable alternative for drilling of Ti6Al4V alloy. 13,14 The laser machining is the non-contact machining operation in which tool wear and vibration can be avoided but accuracy is maintained.…”

Section: Introductionmentioning

confidence: 99%

Drilling of micro-holes on titanium alloy using pulsed Nd:YAG laser: Parametric appraisal and prediction of performance characteristics

Chatterjee

Mahapatra

Bharadwaj

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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Laser drilling is a preferable method in drilling micro and slender holes because of its non-physical contact between the tool and the workpiece leading to elimination of the problems like chatter and vibration. In this article, an experimental investigation of the laser drilling process is carried out on thin sheet (0.5 mm) of titanium alloy (Ti6Al4V) using pulsed Nd:YAG laser. The study investigates the effect of laser parameters such as laser energy, pulse repetition rate, pulse width and gas pressure on hole quality characteristics, namely, circularity at entry and exit, taper and spatter area. Taguchi’s L27 orthogonal array is adopted for conducting the experiments to establish significance of control parameters on the performance measures with less number of experimental run. Analysis of variance shows that laser energy and pulse width significantly influence on circularity, taper and spatter area. Optimal parameter setting for all the performance measures is suggested. Statistically valid empirical models relating hole quality characteristics with laser parameters have been developed based on least square regression analysis. Backpropagation artificial neural network is used predict the output responses considering laser process parameters as inputs. A mean square error within 5% for both the training and testing data suggests the adequacy and robustness of the proposed artificial neural network model. Variation of performance measures with respect to process parameters is predicted through the well-trained artificial neural network model. The pattern of variation exhibits good agreement with the main effect plots obtained through Taguchi method. Artificial neural network model produces mean relative error of 0.001, 0.001, 0.0437 and 0.0234 for circularity at entry, circularity at exit, taper and spatter area, respectively, when compared with experimental values. Since small values of mean relative error are obtained, the proposed artificial neural network model can be satisfactorily used for prediction of quality characteristics of laser micro-drilled holes.

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“…Li et al, [50] carried out research about drilling force, including identified relevant parameters of drilling force, established drilling force model, and verified the proposed model. Glaa et al, [51] developed a numerical model for predicting cutting forces and torque of the drilling process for titanium alloy Ti6Al4V and verified the effectiveness of the model by experimental drilling tests on a vertical machine. Naisson et al, [52] established an analytical model of thrust force and torque of the drilling process, and experimental studies were conducted in various cutting conditions to validate the modeling approach.…”

Section: Literature Reviewmentioning

confidence: 99%

An Improved Rapid Power and Energy Prediction Method of Drilling Process for Sustainable Manufacturing

Jia

Zhang

et al. 2021

IEEE Access

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Energy modeling and energy-saving have attracted extensive attention in the manufacturing industry. Energy monitoring, modeling, and management issues of grinding, milling, and turning processes have been widely studied. However, special research on drilling power and energy consumption needs to be strengthened. The existing drilling power and energy models have the problems of high computational complexity and low practicability. To address this issue, an improved rapid power and energy prediction method of drilling process is proposed in this study. The motivation of the proposed method is to reduce the computational complexity and improve the practicability without losing the predictive accuracy for drilling power and energy. To verify the effectiveness of the proposed method, experimental and case studies were carried out. The results show that the number of formulas, variables, coefficients of the proposed method are all decreased significantly, therefore, the computational complexity is greatly reduced. Meanwhile, power predictive accuracy is improved by 1.91% instead of decreasing compared with the traditional method. Consequently, the simpler model, lower computational complexity, and higher power accuracy make the proposed method more practical in manufacturing industry.INDEX TERMS drilling processes; power prediction; energy prediction; sustainable manufacturing.

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Numerical modeling and experimental analysis of thrust cutting force and torque in drilling process of titanium alloy Ti6Al4V

Cited by 30 publications

References 16 publications

Evaluating Hole Quality in Drilling of Al 6061 Alloys

Evaluating Hole Quality in Drilling of Al 6061 Alloys

Drilling of micro-holes on titanium alloy using pulsed Nd:YAG laser: Parametric appraisal and prediction of performance characteristics

An Improved Rapid Power and Energy Prediction Method of Drilling Process for Sustainable Manufacturing

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