scholarly journals Evaluation of the Surface Defects and Dimensional Tolerances in Multi-Hole Drilling of AA5083, AA6061, and AA2024

2021 ◽  
Vol 11 (9) ◽  
pp. 4285
Author(s):  
Muhammad Aamir ◽  
Majid Tolouei-Rad ◽  
Khaled Giasin ◽  
Ana Vafadar ◽  
Ugur Koklu ◽  
...  
Keyword(s):  
Surface Finish ◽  
Surface Defects ◽  
Hole Drilling ◽  
Drilling Process ◽  
Hole Size ◽  
Industrial Sectors ◽  
Nominal Size ◽  
Circularity Error ◽  
Cylindricity Error ◽  
Side Flow

Drilling is one of the most performed machining operations for riveting and assembly operations in many industrial sectors. The accuracy of the drilled holes and their surface finish play a vital role in the longevity and performance of the machined components, which, in turn, increase productivity. Therefore, this study investigated the effect of the multi-spindle drilling process on dimensional hole tolerances, such as hole size, circularity, cylindricity, and perpendicularity. In addition, the surface defects formed in the holes were examined using scanning electron microscopy. Three aluminium alloys, AA2024, AA6061, and AA5083, which are commonly used in the aerospace, automotive, and marine sectors, were chosen as the study materials. The results showed that the holes drilled in AA2024 gave less circularity error, cylindricity error, and perpendicularity error. In the case of hole size, the holes drilled in AA6061 were less deviated from the nominal size following holes drilled in AA2024 and AA5083 alloys. Surface damage in the form of metal debris adhesion, smeared material, side flow, and feed marks was found on the inner hole surface. Holes drilled in AA5083 alloy had the worst surface finish and were the most oversized, which was associated with noticeable damage and deformations in their inner surface. The ANOVA results revealed that the spindle speed was more influential than feed and mainly affected the hole size and cylindricity errors. However, in the case of circularity error and perpendicularity error, drilling parameters were found to be insignificant.

PENGEMBANGAN ALAT UKUR COMPRESSION TESTER

2019 ◽  
Vol 3 (2) ◽  
pp. 111-118
Author(s):  
Bahtiar Wilantara ◽  
Raharjo Raharjo
Keyword(s):  
Pressure Gauge ◽  
Welding Process ◽  
Field Trials ◽  
Ease Of Use ◽  
Hole Drilling ◽  
Measurement Tool ◽  
Drilling Process ◽  
Measuring Instrument ◽  
Digital Compression ◽  
Materials Used

This study aims to develop an analog compression tester measuring instrument into a digital compression tester as a measurement tool that can provide effectiveness and efficiency to users.                     This research is a research and development or R&D. This research was conducted in several steps, namely: problem identification, information gathering, product design, product manufacture, expert validation, product revision, testing, final production. The development of analog compression tester was first validated by material experts, media experts, and 15 students, and 5 students for field trials. The subjects of this study were vocational students at Taman Karya Madya Teknik Kebumen. Data collection techniques used in this study using instruments in the form of a questionnaire. The data analysis technique of this research is descriptive qualitative and quantitative descriptive percentage.                 The results of the development of digital compression tester designs are: 1) the tools and materials used are electric drill, grinding, cutter, goggles, gloves, masks, ruler, acetaminine welding, screwdriver, scissors, digital dial pressure gauge, hose, spark plugs, clamps , and nepel, 2) the manufacturing process that starts from the cutting process, the hole drilling process, the welding process and the process of connecting between components, 3) the workings of digital compression tester design that is reading the pressure or compression of the machine displayed on the monitor digitally using dial pressure digital gauge, 4) the test results obtained from the validation results from: a) material experts at 89% or Eligible; b) media experts at 85% or reasonable; c) response of field trial students in terms of ease of use and reading of 90% or feasible. Thus, the conclusion that the digital compression tester measuring instrument declared feasible to use for measurement.

scholarly journals Temperature monitoring in the subsurface during single lip deep hole drilling

2020 ◽  
Vol 87 (12) ◽  
pp. 757-767
Author(s):  
Robert Wegert ◽  
Vinzenz Guski ◽  
Hans-Christian Möhring ◽  
Siegfried Schmauder
Keyword(s):  
Cutting Parameters ◽  
Drill Hole ◽  
Machining Process ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Machining Processes ◽  
Deep Hole Drilling ◽  
Feed Force ◽  
Cutting Zone

AbstractThe surface quality and the subsurface properties such as hardness, residual stresses and grain size of a drill hole are dependent on the cutting parameters of the single lip deep hole drilling process and therefore on the thermomechanical as-is state in the cutting zone and in the contact zone between the guide pads and the drill hole surface. In this contribution, the main objectives are the in-process measurement of the thermal as-is state in the subsurface of a drilling hole by means of thermocouples as well as the feed force and drilling torque evaluation. FE simulation results to verify the investigations and to predict the thermomechanical conditions in the cutting zone are presented as well. The work is part of an interdisciplinary research project in the framework of the priority program “Surface Conditioning in Machining Processes” (SPP 2086) of the German Research Foundation (DFG).This contribution provides an overview of the effects of cutting parameters, cooling lubrication and including wear on the thermal conditions in the subsurface and mechanical loads during this machining process. At first, a test set up for the in-process temperature measurement will be presented with the execution as well as the analysis of the resulting temperature, feed force and drilling torque during drilling a 42CrMo4 steel. Furthermore, the results of process simulations and the validation of this applied FE approach with measured quantities are presented.

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.

Non-Contact Online Detection of Concentricity Error

2015 ◽  
Vol 733 ◽  
pp. 611-614
Author(s):  
Hong Zheng
Keyword(s):  
Measurement System ◽  
Three Dimensional ◽  
Error Evaluation ◽  
Dimensional Model ◽  
Online Detection ◽  
Three Dimensional Model ◽  
Geometric Tolerance ◽  
Structural Principle ◽  
Circularity Error ◽  
Cylindricity Error

This paper researches on the non-contact online detection of concentricity error, which mainly focus on the structural principle of the measurement system and the concentricity error evaluation methods. The paper using the method of projection, converting the three-dimensional model to a two-dimensional model and evaluating coaxially error. And it is validated by the simulation of MATLAB. In theory, the proposed measurement system can measure geometric tolerance, including coaxially error, cylindricity error, circularity error, etc.

scholarly journals Comprehensive Research and Analysis of a Coated Machining Tool with a New TiAlN Composite Microlayer Using Magnetron Sputtering

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3633
Author(s):  
Štefan Michna ◽  
Iryna Hren ◽  
Jan Novotný ◽  
Lenka Michnová ◽  
Václav Švorčík
Keyword(s):  
Magnetron Sputtering ◽  
Surface Defects ◽  
Light And Electron Microscopy ◽  
Cutting Tools ◽  
Microstructural Characterization ◽  
High Wear Resistance ◽  
Drilling Process ◽  
Cross Sectional ◽  
Force Microscopy ◽  
New Type

The application of thin monolayers helps to increase the endurance of a cutting tool during the drilling process. One such trendy coating is TiAlN, which guarantees high wear resistance and helps to “smooth out” surface defects. For this reason, a new type of weak TiAlN microlayer with a new composition has been developed and applied using the HIPIMs magnetron sputtering method. The aim of this study was to analyze surface-applied micro coatings, including chemical composition (EDX) and microstructure in the area of the coatings. Microstructural characterization and visualization of the surface structures of the TiAlN layer were performed using atomic force microscopy. To study the surface layer of the coatings, metallographic cross-sectional samples were prepared and monitored using light and electron microscopy methods. The microhardness of the test layer was also determined. Analyses have shown that a 2-to-4-micron thick monolayer has a microhardness of about 2500 HV, which can help increase the life of cutting tools.

Fuzzy Logic in Hole Drilling of Composites

1994 ◽  
Author(s):  
Aditya Thadani ◽  
Athamaram H. Soni
Keyword(s):  
Fuzzy Logic ◽  
Fuzzy Logic Controller ◽  
Thrust Force ◽  
Cutting Speed ◽  
Research Data ◽  
Theoretical Research ◽  
Hole Drilling ◽  
Tool Geometry ◽  
Drilling Process ◽  
And Control

Abstract Experimental and theoretical research data was utilized in building a Fuzzy Logic Controller model applied to simulate the drilling process of composite materials. The objective is to have a better understanding and control of delamination of composites during the drilling process and at the same time to improve the hole finish by controlling fraying and splintering. By controlling the main issues in the drilling process such as feed rate, cutting speed, thrust force, and torque generated in addition to the tool geometry, it is possible to optimize the drilling process avoiding the conventionally encountered problems.

Autonomes Schleifen von Aluminium- und Stahloberflächen/Autonomous grinding of lightweight constructions

2021 ◽  
Vol 111 (01-02) ◽  
pp. 71-76
Author(s):  
Hannah Pulli ◽  
Jan Oliver Brassel ◽  
Michael Wilhelm Drechsel ◽  
Mathias Mayer ◽  
Jürgen Fleischer ◽  
...  
Keyword(s):  
Surface Finish ◽  
Surface Defects ◽  
Process Automation ◽  
Software And Hardware ◽  
The Way

Zur Umsetzung des autonomen Schleifens ist eine Kombination aus Software und Hardware notwendig. Die Verbindung ermöglicht die Steigerung von Produktivität und Reproduzierbarkeit. In diesem Forschungsbeitrag werden ein Überblick über die Identifikation und Klassifizierung von Fehlerstellen auf Karosserieoberflächen gegeben sowie automatisierte Schleifversuche vorgestellt, die schließlich den Weg zur Prozessautomation zeigen.   Automating surface-finish of single car-bodies requires to combine software and hardware. Thus, productivity and reproducibility can be increased. This paper focuses on correctly detecting and classifying relevant surface defects. The analysis of fundamental grinding experiments on testing sheets points out the way to process automation.

scholarly journals Significant Reduction in Energy Consumption and Carbon Emission While Improving Productivity in Laser Drilling of CFRP Sheets with a Novel Stepped Process Parameter Parallel Ring Method

2022 ◽  
Vol 6 (1) ◽  
pp. 7
Author(s):  
Menghui Zhu ◽  
Chao Wei ◽  
Wei Guo ◽  
Zhizhou Zhang ◽  
Jinglei Ouyang ◽  
...  
Keyword(s):  
Ring Laser ◽  
Energy Input ◽  
Processing Parameters ◽  
Laser Drilling ◽  
Parent Material ◽  
Hole Drilling ◽  
Drilling Process ◽  
Cfrp Sheets ◽  
Hole Drilling Method ◽  
Drilling Quality

Although laser drilling of carbon fibre-reinforced polymer (CFRP) composites offers the advantages of zero tool-wear and avoidance of fibre delamination compared with mechanical drilling, it consumes considerably more energy during the drilling process. This research shows that by using a new, stepped parameter parallel ring laser hole drilling method, an energy saving of 78.10% and an 18.37 gCO2 reduction for each hole, while improving productivity by more than 300%, can be achieved in laser drilling of 6 mm diameter holes in CFRP sheets of 2 mm in thickness, compared with previous laser drilling methods under the same drilling quality. The key reason for this is an increase in energy input to the inner rings enabling more rapid removal of the material, while the lower energy input for the outer ring provides a shielding trench to reduce the heat loss into the parent material. The results are compared with single-ring laser drilling and multiple-ring laser drilling with constant processing parameters, and a discussion is given on comparing with mechanical drilling and future prospects, including a combined mechanical drilling and laser pre-scribing process.

Sign in / Sign up

Export Citation Format

Share Document