scholarly journals Temperature evaluation and performance comparison of various cooling techniques in drilling of grade 5 titanium alloy

2021 ◽  
pp. 213-213
Author(s):  
Nivin Joy ◽  
S. Prakash ◽  
A. Krishnamoorthy ◽  
A. Anderson
Keyword(s):  
Optimum Condition ◽  
Feed Rate ◽  
Cutting Forces ◽  
Thrust Force ◽  
Response Surfaces ◽  
Cryogenic Cooling ◽  
Interface Temperature ◽  
Drilling Process ◽  
Grade 5 ◽  
The Impact

Heat dissipation is a foremost issue in machining of materials and to overcome this different cooling techniques are adopted to improve the surface integrity and diminish microstructural damage and to effectively flush chips produced. In this research, machinability of titanium grade 5 (Ti-6Al-4V) was carried out through drilling process considering three different cooling procedures like cryogenic cooling (CO2), palm oil based minimum quantity lubrication (MQL) and wet/flood cooling with general cutting fluid (emulsifiers). Experiments were prearranged in par with Taguchi?s technique and a suitable L18 orthogonal array was formulated and the outputs obtained viz., interface temperature and cutting forces (torque/thrust force) were analyzed by adopting response surface methodology (RSM). For interface temperature, type of coolant is the most influencing factor, whereas for cutting forces, the impact of feed rate, drill speed and type of coolant are significant. Response surfaces were fitted for the outputs and subsequently a higher polynominal regression equation was developed for prediction. The optimum condition obtained for constraint multiobjective optimization using desirability approach was: drill speed of 42.49 m/min, feed rate of 0.05 mm/rev and cooling type as cryogenic cooling. The main objecive is to minimize the interface temperature and torque subjected to the constraint thrust force (?1500 N). Confirmation experiment performed with optimum condition displays a significant enhancement in output results.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

Experiments of Drilling Titanium Alloy with Varying Operation Parameters

2017 ◽  
Vol 748 ◽  
pp. 254-258
Author(s):  
Chang Yi Liu ◽  
Bai Shou Zhang ◽  
Suman Shrestha
Keyword(s):  
Titanium Alloy ◽  
Feed Rate ◽  
Thrust Force ◽  
Maximum Amount ◽  
Spindle Speed ◽  
Drilling Process ◽  
Process Variables ◽  
Experimental Cutting ◽  
Operation Parameters ◽  
Titanium Alloy Ti6al4v

Drilling experiments of titanium alloy Ti6Al4V were conducted. Taking the speed and feed as the process variables, a set of experimental cutting forces are obtained and compared. From the experimental results it is concluded that within the experimental extent the thrust force and torque of drilling process rises with the feed rate. The lower spindle speed resulted in the greater amount of thrust. Feed rates have greater influence on the thrust force than the spindle speed. The combination of greater feed rate and lower spindle speed results in the maximum amount of thrust. However, combination of greater feed rate and spindle speed resulted in maximum amount of torque.

Effects of Twist Drill Point Angle on Thrust Force and Delamination Factor in Hybrid Fiber Composites Drilling

2014 ◽  
Vol 564 ◽  
pp. 501-506 ◽  
Author(s):  
Mohd Azuwan Maoinser ◽  
Faiz Ahmad ◽  
Safian Shariff ◽  
Tze Keong Woo
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Polymeric Composite ◽  
Drilling Process ◽  
Twist Drill ◽  
Fiber Reinforced ◽  
Hybrid Fiber ◽  
Frp Composites ◽  
Delamination Factor ◽  
Drill Point

Drill point angle of twist drill has a significant effect on thrust force and delamination factor on drilled holes in fiber reinforced polymer (FRP) composites. In this study, three drill point angle of twist drill; 85°, 118° and 135° were used to drill holes in hybrid fiber reinforced polymeric composite (HFRP). HFRP composites were fabricated using vacuum infusion molding (VIM) technique. The test samples were cured at 90°C for two hours. In drilling process various drill point angle and feed rate were employed to investigate the effect of both parameters on thrust force and delamination factor when drilling the HFRP composite. The results showed that small drill point angle and low feed rate can reduce the thrust force leading to the reduction of damage factor at the holes entrance and exit.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

Drilling Force and Chip Morphology in Drilling of PCB Supported Hole

2011 ◽  
Vol 188 ◽  
pp. 429-434 ◽  
Author(s):  
L.P. Yang ◽  
Li Xin Huang ◽  
Cheng Yong Wang ◽  
L.J. Zheng ◽  
Ping Ma ◽  
...  
Keyword(s):  
Feed Rate ◽  
Printed Circuit Board ◽  
Thrust Force ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Circuit Board ◽  
Drilling Process ◽  
Drilling Force ◽  
Drill Bits

Supported holes of Printed circuit board (PCB) are drilled with two different drill bits. Drilling force (thrust force and torque) and chip morphology are examined at different cutting parameters, and the effects of the two drills are discussed. The results indicate that the drilling force and chip morphology are affected by the feed rate, spindle speed and drill shape. Thrust force increases with the increasing feed rate, and decreases with the increasing spindle speed. Optimization of drill geometry can reduce the thrust force significantly, and is effective in chip breaking which can improve the chip evacuation during the drilling process.

Finite Element Method Simulation of Drilling Process on Metal-Matrix Composites

2011 ◽  
Vol 188 ◽  
pp. 372-375
Author(s):  
H.L. Zhang ◽  
Jin Chen
Keyword(s):  
Finite Element ◽  
Feed Rate ◽  
Shear Failure ◽  
Thrust Force ◽  
Equivalent Stress ◽  
Damage Model ◽  
Cutting Speed ◽  
Finite Element Method Simulation ◽  
Drilling Process ◽  
Machining Processes

Drilling is one of the complex machining processes, which has been widely applied in the manufacturing area. In this paper, a 3D coupled thermo-mechanical finite element model was used for simulating the thrust force, torque and von Mises equivalent stress at different cutting conditions. The J-C damage model (shear failure) was used in conjunction with the J-C plasticity model, as well as the continuous adaptive remeshing technical. The results show that the thrust force and torque increase with the increasing of the cutting speed and feed rate, and the influence of the feed rate is more obviously.

Research on Drilling Process of Nickel-Based Super-Alloy

2010 ◽  
Vol 33 ◽  
pp. 373-377
Author(s):  
Jian Wu ◽  
Rong Di Han
Keyword(s):  
Feed Rate ◽  
Empirical Formula ◽  
Inconel 718 ◽  
Thrust Force ◽  
Shear Angle ◽  
Drilling Process ◽  
Deformation Characteristics ◽  
Drilling Speed ◽  
Aisi 1045 ◽  
Super Alloy

Nickel-based super-alloy belongs to difficult-to-machine materials, its machinability is low. To find out the difficulties of drilling nickel-based super-alloy, it is necessary to study the drilling process. The study on the drilling process of nickel-based super-alloy Inconel 718 is discussed from two aspects, drilling deformation and drilling forces distribution. For studying the drilling deformation characteristics and influence laws, the drilling chip specimens are obtained by using self-made drilling quick-stop device. Then, the empirical formula of shear angle is also given. Finally, the drilling forces distribution is studied. Results shows that: drilling deformation decreases when the distance to chisel edge, drilling speed and feed rate increases; drilling deformation of Inconel 718 is larger than AISI 1045; the ratio of torque and thrust force on the lead cutting edge is 29%~33%, 74%~77%, respectively; the torque and thrust force of Inconel 718 is about 1.8~2.3 times than that of AISI 1045.

A Study of the Drilling Process

1974 ◽  
Vol 96 (4) ◽  
pp. 1207-1215 ◽  
Author(s):  
R. A. Williams
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Three Dimensional ◽  
Drilling Process ◽  
Two Dimensional ◽  
Twist Drill ◽  
Feed Velocity ◽  
Cutting Geometry ◽  
Drill Point ◽  
Finite Thrust

Drilling is a complex three dimensional cutting process yet it is possible to simulate the action of a two flute twist drill with two dimensional models provided consideration is given to the influence of the feed velocity on the cutting geometry at the drill point. Two models of chip formation and an indentation model are developed to simulate the action of the drill point. From these models equations are derived for the prediction of total torque and thrust given the cutting conditions, drill geometry, and an empirical factor which is related to the work material. Computed values of torque and thrust are shown to compare favorably with those obtained from drilling tests on an 0.45 percent C steel. The shape and magnitude of the wear zone about the chisel edge is estimated and it is shown that the observed finite thrust force as the feed rate approaches zero can be attributed to the “cutting” action of the chisel edge.

Optimasi Multirespon Gaya Tekan Dan Momen Torsi Pada Penggurdian Material Komposit Glass Fiber Reinforce Polymer (Gfrp) yang Ditumpuk Dengan Material Stainless Steel (SS) Menggunakan Metode Algoritma Genetika

2019 ◽  
Vol 9 (01) ◽  
pp. 1-5
Author(s):  
Angga Sateria
Keyword(s):  
Stainless Steel ◽  
Glass Fiber ◽  
Process Parameters ◽  
Feed Rate ◽  
Thrust Force ◽  
Spindle Speed ◽  
Quality Characteristic ◽  
Drilling Process ◽  
Glass Fiber Reinforced ◽  
Different Levels

Glass fiber reinforced polymer (GFRP)-stainless steel stacks used in the aircraft structural components. The assembly process of this components requires mechanical joining using bolt and nut. The drilling process is commonly used for producing hole to position the bolt correctly. Thrust force and torque are responses that used to evaluate the performance of drilling process. The quality characteristic of these responses are “smaller-is-better.” The aim of this experiment is to identify the combination of process parameters for achieving required multiple performance characteristics in drilling process of GFRP-stainless steel stacks materials. The three important process parameters, i.e., point angle, spindle speed, and feed rate were used as input parameters. Point angle was set at two different levels, whilethe other two were set at three different levels. Hence, a 2 x 3 x 3 full factorial was used as designexperiments. The experiments were replicated two times. The optimization was conducted by using genetic algorithm method. The minimum thrust force and torque could be obtained by using point angle, spindle speed and feed rate of 118o, 2383 rpm, 62 mm/min respectively.

Analysis of Thrust Force and Torque in Drilling Process of Particle Board

2015 ◽  
Vol 818 ◽  
pp. 233-238
Author(s):  
Krzysztof Szwajka
Keyword(s):  
Mathematical Models ◽  
Cutting Forces ◽  
Thrust Force ◽  
Surface Characteristics ◽  
Cutting Parameters ◽  
Machining Process ◽  
Drilling Process ◽  
Machining Parameters ◽  
Particle Board ◽  
Wood Based Composite

Particleboard is a wood based composite extensively used in wood working. Drilling is the most commonly used machining process in furniture industries. The surface characteristics and the damage free drilling are significantly influenced by the machining parameters. The thrust force developed during drilling play a major role in gaining the surface quality and minimizing the delamination tendency. In this study trials were made eighteen durability tools for different values of the parameters analyzed cut. Based on the results obtained from the study, the effect of cutting parameters selected signals of axial force and torque cutting. Proposed mathematical models using ANOVA, allowing to estimate the cutting forces.

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