The effects of minimum quantity lubrication and cryogenic liquid nitrogen cooling on drilled hole quality in GLARE fibre metal laminates

Giasin, Khaled; Ayvar-Soberanis, Sabino; Hodzic, A.

doi:10.1016/j.matdes.2015.10.049

Cited by 51 publications

(70 citation statements)

References 16 publications

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“…It was also observed that the holes oversize was greater at bottom in most holes with the exception of holes drilled at n = 3000 rpm and f = 300 mm/min and f = 900 mm/min, and n = 3000 rpm and f = 600 mm/min, which be attributed to the cutting vibration and the instability of the workpiece as the feed rate increased [37]. It was reported in one of our previous studies that the hole size is likely to shrink with depth when drilling GLARE fibre metal laminates [19]. However, the relatively smaller thickness of the laminate used for the current study might not allowed for the promotion of high cutting temperature enough to cause a significant reductions in hole size at both locations.…”

Section: Hole Size and Error Of Circularitymentioning

confidence: 78%

“…6 Measurement setup of hole size and error of circularity using CMM machine and description of MIC method [19,24] delamination analysis and damage analysis of borehole surface. The results regarding cutting forces are discussed first.…”

Section: Resultsmentioning

confidence: 99%

“…2 Details of GLARE 2B-4/3-0.4 workpiece used for the drilling trials (a) Layup of GLARE 2B laminate (b) Top view of GLARE laminate [19] (c) Side view of GLARE 2B 4/3 laminate viscosity will be low enough to allow it to flow easily during the compression process and suppreess the voids preventing the damage to occur in Aluminium sheets [18]. The Aluminium sheets surface are pre-treated and degreased followed by an anodising process using an acid and subsequent priming with BR-127 corrosion inhibiting bond primer.…”

Section: Materials Specificationmentioning

confidence: 99%

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3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

Giasin

Ayvar-Soberanis

French³

et al. 2016

Appl Compos Mater

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Machining Glass fibre aluminium reinforced epoxy (GLARE) is cumbersome due to distinctively different mechanical and thermal properties of its constituents, which makes it challenging to achieve damage-free holes with the acceptable surface quality. The proposed work focuses on the study of the machinability of thin (~2.5 mm) GLARE laminate. Drilling trials were conducted to analyse the effect of feed rate and spindle speed on the cutting forces and hole quality. The resulting hole quality metrics (surface roughness, hole size, circularity error, burr formation and delamination) were assessed using surface profilometry and optical scanning techniques. A three dimensional (3D) finite-element (FE) model of drilling GLARE laminate was also developed using ABAQUS/Explicit to help understand the mechanism of drilling GLARE. The homogenised ply-level response of GLARE laminate was considered in the FE model to predict cutting forces in the drilling process.

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Section: Hole Size and Error Of Circularitymentioning

confidence: 78%

Section: Resultsmentioning

confidence: 99%

Section: Materials Specificationmentioning

confidence: 99%

See 1 more Smart Citation

3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

Giasin

Ayvar-Soberanis

French³

et al. 2016

Appl Compos Mater

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“…It was also reported that two flute twist drills gave less delamination and burr formations compared to three-flute and four-and eight-facet drills [13]. The use of coolants during drilling of GLARE® was found to reduce burr formations, enhance borehole surface finish, and lower the workpiece temperature [8,9]. The laminate thickness and fiber orientation of composite layers were found to influence a number of hole quality parameters and cutting forces [8,9,12,14].…”

Section: Introductionmentioning

confidence: 96%

The effect of drilling parameters, cooling technology, and fiber orientation on hole perpendicularity error in fiber metal laminates

Giasin

2018

Int J Adv Manuf Technol

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Conventional twist drilling is a widely used machining process for creating holes in aerospace and automobile structures. Drilling at room temperature can sometime affect the quality of machined holes due to increased thermal effects on the workpiece. Thermal effects can be a cumbersome when machining composites and fiber metal laminates due to their different thermal expansion coefficients, which may introduce additional stress in the structure. Thermal machining effects can be minimized using coolants supplied either directly or indirectly to the cutting tool-workpiece interaction zone, to remove away part of the generated heat. The use of coolants adds extra costs for handling, disposal, and environmental impact. Therefore, environmentally friendly cooling technologies are replacing conventional cooling methods to reduce costs and impact on the environment. In addition, the selection of machining parameters has great influence on the hole quality. This paper investigates the impact of drilling parameters and two modern cooling technologies namely cryogenic liquid nitrogen and minimum quantity lubrication on the hole perpendicularity error of fiber metal laminates commercially known as GLARE® (Glass Laminate Aluminum Reinforced Epoxy). It was also found that applying cryogenic liquid nitrogen or minimum quantity lubrication does not lead to an improvement in hole perpendicularity error in GLARE® laminates.

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“…Kriyojenik soğutma ile kesme sıcaklıklarının düşürülmesinin malzemeyi gevrekleştirdiği, sünekliği azalan iş parçası malzemesinde daha az çapak oluşumunun gerçekleştiği tespit edilmiştir. Bir başka çalışmada ise [22], GLARE kompozit malzemelerin delinmesinde delik kalitesi kuru, minimum miktarda yağlama ve kriyojenik şartlar altında araştırılmıştır. Kriyojenik şartlarda kuru şartlar ile kıyaslandığında delik çıkışındaki çapak yüksekliklerinde %47'ye varan düşüş gözlemlenmiştir.…”

Section: Gi̇ri̇ş (Introduction)unclassified

Inconel 718 süperalaşımının delinmesinde kriyojenik soğutmanın delme performansı üzerine etkilerinin araştırılması

Uçak

Çıçek²

2018

Gazi Üniversitesi Mühendislik-Mimarlık Fakültesi Dergisi

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Highlights:Graphical/Tabular Abstract  Drilling of Inconel 718 superalloy under cryogenic conditions with solid carbide drills  Temperature measurement depending on cutting depth  Improvement of surface integrity with cryogenic conditions Drilling of Inconel 718 which is a nickel-based superalloy is a challenging process because its superior physical and mechanical properties lead to the high thermal and mechanical loads on a twist drill. In order to obtain desired hole quality, excessive heat and forces generated during drilling must be minimized using suitable coolants and/or lubricants. Figure A. Cutting conditions, thermocouple connection setup, and the obtained cutting temperature, torque and thrust force results.Purpose: This study aims to investigate experimentally the effects of cryogenic cooling on cutting performance in drilling of Inconel 718.Theory and Methods: Drilling tests were performed at a constant cutting speed (10 m/min) and a feed (0.02 mm/rev) using uncoated and TiAlN coated solid carbide twist drills under cryogenic, wet and dry conditions. The effects of cooling/lubrication conditions and coating material were examined in terms of thrust force, torque, cutting temperature, burr formation, chip formation, subsurface deformed layer thickness, microhardness change and average surface roughness. Results:Cryogenic cooling significantly decreased the cutting temperatures. In general, lower subsurface deformed layer thickness and burr formation at the hole entrance were obtained under cryogenic conditions. However, experimental results showed that cryogenic cooling increased the thrust force and the torque values and led to rapid tool wear. Therefore, burr formation at the hole exit also increased. Good surface roughness and low tool wear were achieved under wet conditions.Conclusion: Due to absence of any cooling/lubrication media, dry conditions led to higher cutting force, torque, and temperatures and undesirable surface quality. The test results showed that although it is possible to obtain better surface quality under cryogenic conditions, extremely low temperatures affected the cutting performance adversely. On the other hand, due to its moderate cooling and lubrication properties, wet conditions provided more stable cutting and better drilling performance.

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The effects of minimum quantity lubrication and cryogenic liquid nitrogen cooling on drilled hole quality in GLARE fibre metal laminates

Cited by 51 publications

References 16 publications

3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

The effect of drilling parameters, cooling technology, and fiber orientation on hole perpendicularity error in fiber metal laminates

Inconel 718 süperalaşımının delinmesinde kriyojenik soğutmanın delme performansı üzerine etkilerinin araştırılması

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