Optimization of facing process by indigenously developed force dynamometer

Drilling is considered as one of the more challenging problems in the aerospace structures stringent tolerance required for fasteners such as rivets and bolts to join the mating parts for the final assembly. Fiber-reinforced polymers are widely used in aeronautical applications due to their superior properties. One of the major challenges lays in the machining such polymers is the poor drilled-hole quality which reduces the strength of the composite and leads to part rejection at the assembly stage. In addition, rapid tool wear due to the abrasive nature of composites requires frequent tool change which result in high tooling and machining costs. This review intended to give in-depth details on the progress of drilling of fiber-reinforced polymers with special attention given to carbon fiber reinforced polymers. The objective is to give a comprehensive understanding of the role of drilling parameters and composite properties on the drilling induced damage in machined holes. Also, the review looks into the drilling process parameters and its optimization techniques, and the effects of dust/ aerosols on human health during the machining process. This review will provide the scientific and industrial communities with their advantages and disadvantages through better drilled-hole quality inspection.

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“…Optimization techniques play a significant role in the selection of the best process parameters [136].…”

Section: Optimization Of Process Parametersmentioning

confidence: 99%

Recent advances in drilling of carbon fiber–reinforced polymers for aerospace applications: a review

Aamir

Tolouei‐Rad

Giasin³

et al. 2019

Int J Adv Manuf Technol

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197

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“…The Taguchi method is useful for determining the best combination of factors under desired experimental conditions [5]. The Taguchi method reduces a large number of experiments that could be required in traditional experiments when the number of process parameters increases [6]. In the Taguchi method, an orthogonal array is designed that studies the entire parameter space with a small number of experiments [7].…”

Section: Introductionmentioning

confidence: 99%

Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach

Aamir

Tolouei‐Rad

et al. 2020

Materials

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In industries such as aerospace and automotive, drilling many holes is commonly required to assemble different structures where machined holes need to comply with tight geometric tolerances. Multi-spindle drilling using a poly-drill head is an industrial hole-making approach that allows drilling several holes simultaneously. Optimizing process parameters also improves machining processes. This work focuses on the optimization of drilling parameters and two drilling processes—namely, one-shot drilling and multi-hole drilling—using the Taguchi method. Analysis of variance and regression analysis was implemented to indicate the significance of drilling parameters and their impact on the measured responses i.e., surface roughness and hole size. From the Taguchi optimization, optimal drilling parameters were found to occur at a low cutting speed and feed rate using a poly-drill head. Furthermore, a fuzzy logic approach was employed to predict the surface roughness and hole size. It was found that the fuzzy measured values were in good agreement with the experimental values; therefore, the developed models can be effectively used to predict the surface roughness and hole size in multi-hole drilling. Moreover, confirmation tests were performed to validate that the Taguchi optimized levels and fuzzy developed models effectively represent the surface roughness and hole size.

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“…As the feed was increased, the increased, while increasing the spindle speed showed less variation in . The high generation of due to the high feed meant that the tool penetrated faster; therefore, at high feed, the tool has to cut maximum material from the workpiece, which increased the due to an increase in uncut chip thickness [28,29].…”

Section: Analysis Of Thrust Forcementioning

confidence: 99%

Multi-spindle drilling of Al2024 alloy and the effect of TiAlN and TiSiN-coated carbide drills for productivity improvement

Aamir

Tolouei‐Rad

Giasin

2021

Int J Adv Manuf Technol

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High precision drilling is required to ensure the structural integrity of the aircraft. Therefore, strict quality controls are required to ensure optimum hole quality since hundreds of thousands of holes are drilled into different aircraft structures. The large number of holes required for riveting means that their installation must be carried out in a fast and precise manner. This can be achieved using multi-head drilling tools that can drill several holes simultaneously. The current study investigated the use of a multi-spindle drill head that can produce three holes simultaneously. Uncoated carbide and TiAlN-and TiSiN-coated carbide drills were used to assess cutting forces, hole surface roughness, burr formations and tool condition when machining Al2024 aerospace alloy under dry machining conditions. Analysis of variance was employed for estimating the relationships between the input parameters (spindle speed, feed and tool coating) and the studied hole quality metrics. Further, a regression model was developed with a regression coefficient (R 2 ) of more than 90% for the prediction of measured responses. Interestingly, better results in lower thrust force and surface roughness were obtained using the uncoated carbide drills compared with TiAlN and TiSiN. While the performance of TiAlN was found to be better than those obtained from TiSiN.

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Optimization of facing process by indigenously developed force dynamometer

Cited by 26 publications

References 22 publications

Recent advances in drilling of carbon fiber–reinforced polymers for aerospace applications: a review

Recent advances in drilling of carbon fiber–reinforced polymers for aerospace applications: a review

Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach

Multi-spindle drilling of Al2024 alloy and the effect of TiAlN and TiSiN-coated carbide drills for productivity improvement

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