Recent Research Progress in Deep Hole Drilling Process: A Review

Chandar, J. Bharani; Nagarajan, Lenin; Kumar, M. Siva

doi:10.1142/s0218625x21300033

Cited by 13 publications

(8 citation statements)

References 93 publications

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“…It is clear that exp2 (f z = 0.0045 mm/tooth, v c = 17.56 m/min) presents the most stable cut with an increase in the thrust force peaks in the last part of the drilling operation where the hole is deeper and consequently the chip evacuation is hindered (Figure 14b). The reason behind the stability of exp2 might reside in the combination of the thermal softening induced by the high levels of cutting speed and the quick chip extraction caused by the feed rate v f defined in Equation (2).…”

Section: Discussionmentioning

confidence: 99%

“…Deep microdrilling is a very complex manufacturing process, typically employed when there is a need for precise control over hole diameter, coupled with a requirement for excellent straightness and surface finish. It is usually referred to as deep drilling when the hole depth D is 10 times larger than the nominal hole diameter d [1,2]. Therefore, the aspect ratio (AR) D/d > 10 is defined.…”

Section: Introductionmentioning

confidence: 99%

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A Cutting Force and Hole Geometry Study for Precision Deep-Hole Microdrilling of Magnesium

Pizzi,

Costetti,

De Gaetano

et al. 2024

Micromachines

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Size effects, high thrust forces, limited heat dissipation, and tool deterioration are just some of the challenges that deep microdrilling poses, underscoring the importance of effective process control to ensure quality. In this paper, an investigation performed on a microdrilling process on pure magnesium using a 0.138 mm diameter microdrill to achieve an aspect ratio equal to 36 is proposed. The effect of the variation of the cutting parameters feed per tooth fz and cutting speed vc was studied on thrust force, supporting hole quality evaluation in terms of burr height, entrance, and inner diameters. The results showed that fz significantly influences the hole quality. In fact, as fz increases, the burr height decreases and the inner diameter approaches the nominal diameter. However, optimizing the hole geometry with high feed per tooth values increases the thrust forces, compromising tool life. In fact, a significant dependence of the thrust force on both cutting parameters was found. In this scenario, increasing vc can mitigate the high thrust forces by inducing material softening. The study results improve precision manufacturing by refining parameters, ensuring the quality and reliability of magnesium-based microcomponents.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Cutting Force and Hole Geometry Study for Precision Deep-Hole Microdrilling of Magnesium

Pizzi,

Costetti,

De Gaetano

et al. 2024

Micromachines

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“…These are conventional methods of drilling deep holes, such as, e.g., Gun Drilling (GD), Boring and Trepanning Association (BTA) deep-hole drilling, and Single Lip Drilling (SLD), and unconventional methods such as Electro-Chemical Machining (ECM), Laser Beam Machining (LBM), Electro Discharge Machining (EDM), and Abrasive Water Jet Machining (AWJM). They elaborated and described in detail the parameters entering the drilling process under individual methods and the direction of the research activity in this area of hole formation technology [9].…”

Section: State Of the Artmentioning

confidence: 99%

Influence of Coolant Properties and Chip Former Geometry on Tool Life in Deep Drilling

Kočiško,

Pollák,

Grozav

et al. 2023

Applied Sciences

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The aim of the article is to find a correlation between a change in the properties of the cooling agent and a change in the geometry of the chipformer, as both are reflected in the service life of the tool after deep drilling. The reason for carrying out the research is the requirement of practice to obtain the economic efficiency of the production of such a demanding process as deep drilling. When applying the latest designs of gun drills, it is very important to correctly set the technological parameters to maintain the stability of the cutting process. One of the most important parameters is the correct removal of heat from the cutting site, and this will be ensured by the stability of pressure, temperature, and percentage of emulsion in the cooling medium, as well as the adjustment of the geometry of the chip former. On this basis, a large number of tests were carried out, consisting of testing the number of drilling cycles carried out by new, unfluted gun drills at constant feed rates and spindle rotation frequencies. After testing, it is possible to modify and supplement the existing methodology of deep drilling technology in terms of managing the cooling emulsion and chip-forming geometry. The tests were aimed at increasing the service life and the number of possible re-grindings of the gun drills depending on changes in the percentage of the emulsion concentration, the pressure and temperature of the cooling agent, and the associated chipformer geometry.

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“…Due to the small diameter of the chip removal channel of the tool, it is difficult for chips to be discharged from the chip removal channel when drilling deep holes of less than φ 16 mm. Therefore, the BTA deep-hole drilling system mainly processes holes from φ 18∼65 mm [7,8]. To analyze the influence of different process parameters on the machining state, the spindle speed was set to 145 r/min and 195 r/min, and the feed was set to 0.06 mm/r and 0.12 mm/r.…”

Section: Specimens and Experimental Processmentioning

confidence: 99%

“…Although TA10 alloy has excellent mechanical properties, it is a typically difficult-to-machine material; its high strength and high hardness lead to high requirements for deep hole drilling; and it poses a challenge due to the closed environment, the difficulty of observation, and the difficulty of chip removal [5,6]. The deep-hole drilling system for machining TA10 alloy can be divided into gun drilling system, BTA system, jet suction drilling system, and DF system according to its chip removal method and cooling method [7,8]. Among them, the BTA system is widely used due to its advantages of high machining quality, wide machining range, and stable performance [9].…”

Section: Introductionmentioning

confidence: 99%

Multiobjective Optimization of Cutting Parameters for TA10 Alloy Deep-Hole Drilling

et al. 2022

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In order to obtain better quality TA10 pipes, the Boring and Trepanning Association (BTA) deep-hole drilling process is used. However, this type of machining leads to difficult chip removal, tool wear, and poor hole-surface quality. In this study, a deep-hole drilling experiment was conducted on TA10 workpieces using the designed tool with different process parameters, and the process parameters were optimized by machining results with multiple objectives such as chip morphologies, tool wear, hole-axis deflection, and hole surface roughness. The results show that different process parameters have a great impact on the cutting process, with a higher feed resulting in smoother chip removal and a lower spindle speed resulting in lighter tool wear and less hole axis deflection. When the spindle speed is 145 r/min and the feed is 0.12 mm/r, the machined TA10 pipe meets both the accuracy requirement of roughness and the machining efficiency.

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Recent Research Progress in Deep Hole Drilling Process: A Review

Cited by 13 publications

References 93 publications

A Cutting Force and Hole Geometry Study for Precision Deep-Hole Microdrilling of Magnesium

A Cutting Force and Hole Geometry Study for Precision Deep-Hole Microdrilling of Magnesium

Influence of Coolant Properties and Chip Former Geometry on Tool Life in Deep Drilling

Multiobjective Optimization of Cutting Parameters for TA10 Alloy Deep-Hole Drilling

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