scholarly journals An Experimental Investigation on Bushing Geometrical Properties and Density in Thermal Frictional Drilling

2018 ◽  
Vol 8 (12) ◽  
pp. 2658
Author(s):  
Zülküf Demir ◽  
Cebeli Özek ◽  
Muhammed Bal
Keyword(s):  
Experimental Investigation ◽  
Aluminum Alloys ◽  
Wall Thickness ◽  
High Speed ◽  
High Speed Steel ◽  
Volume Ratio ◽  
Geometrical Properties ◽  
Friction Drilling ◽  
Tool Diameter ◽  
Geometrical Dimensions

In thermal friction drilling (TFD) operations, the geometrical dimensions of bushing shape, height and wall thickness are the most vital consequences, since these increase the connecting length and strength. In this paper, AA7075-T651 aluminum alloys with 2, 4, 6, 8, and 10 mm thicknesses were drilled with the TFD process in order to investigate density, volume ratio, and height and wall thickness of the bushings. The experiments were conducted at constant spindle speed and feed rate conditions by using High Speed Steel (HSS) conical tools of 5, 10, 15, and 20 mm in diameter. It was experimentally found that the bushing height and the wall thickness had a tendency to increase linearly with the increase in both material thickness and tool diameter. The effect of tool diameter was found to have more influence on the measurable values than the thickness of the drilled material. The density of the bushing changed trivially. Approximately 70–75 percent of the evacuated material formed the bushing shape in TFD operations.

scholarly journals An Experimental Investigation on Bushing Geometrical Properties and Density, in Thermal Frictional Drilling

2018 ◽  
Author(s):  
Zülküf Demir ◽  
Cebeli Özek ◽  
Muhammed Bal
Keyword(s):  
Experimental Investigation ◽  
Aluminum Alloys ◽  
Wall Thickness ◽  
Feed Rate ◽  
Volume Ratio ◽  
Spindle Speed ◽  
Geometrical Properties ◽  
Friction Drilling ◽  
Tool Diameter ◽  
Geometrical Dimensions

In thermal friction drilling (TFD) operations, the geometrical dimensions of bushing shape, height and wall thickness are the most vital consequences, due to increasing the connecting length and strength. In this paper, AA7075-T651 aluminum alloys with 2, 4, 6, 8, and 10 mm in thicknesses were drilled with TFD process in order to investigate the density, the volume ratio, and height and wall thickness of the bushings. The experiments were conducted at constant spindle speed and feed rate conditions by using HSS conical tools of 5, 10, 15, and 20 mm in diameters. It was experimentally found that the bushing height and the wall thickness were tendency of increase linearly with increasing both material thickness and tool diameter. The effect of tool diameter was found to have much of influence on the measured values than the thickness of the drilled material. The density of the bushing was changed inconsiderably. Approximately 70-75 % percentages of the evacuated material composed the bushing shape, in TFD operations.

Experimental Investigation on High-Speed Milling of Aluminum Alloys

2011 ◽  
Vol 418-420 ◽  
pp. 1141-1147
Author(s):  
Yong Liu ◽  
Li Tang Zhang ◽  
Zhi Hong Xu
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Experimental Investigation ◽  
Aluminum Alloys ◽  
High Speed ◽  
Depth Of Cut ◽  
Processing Temperature ◽  
Single Factor ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling is recognized as one of rapidly development machining methods. The article gives details of machining experiments with different aluminum alloys. Through a lot of single factor experiments and the orthogonal multi-factor experiments, and also use method of semi-artificial thermocouple. This paper mainly studies influence of surface roughness and residual stress with changed rotate speed, tooth load and radial depth of cut, and changed law of processing temperature for rotate speed. Though experiments shows that enhancing rotate speed may reduce surface roughness and residual stress within certain limits and the result of experiments is not agree with Carl Salomon’s theory.

Tool Wear of Diamond-Like Carbon-Coated High-Speed Steel with a Cr-Based Interlayer in Cutting of Aluminum Alloys

2012 ◽  
Vol 152-154 ◽  
pp. 74-79
Author(s):  
Tadahiro Wada ◽  
Koji Iwamoto ◽  
Hiroaki Sugita
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Diamond Like Carbon ◽  
Aluminum Alloy 6061 ◽  
Coated Tool ◽  
Alloy 6061

In cutting aluminum alloy 6061, continuous chips have a negative influence on the machining operation. Usually, Pb is added in order to break continuous chips. However, from the standpoint of environmental protection, it is necessary to improve chip breakability without adding Pb. One effective measure to improve chip breakability is by adding Si to aluminum alloy 6061. However, the influence of Si content on tool wear has not been fully examined. In this study, in order to clarify the influence of a diamond-like carbon (DLC) coating layer with a Cr-based interlayer, namely (Al,Cr)N, on cutting performance, aluminum alloys having different Si contents were turned. The substrate of the tool material was high-speed steel (1.4%C). The tool wear and the surface roughness were experimentally investigated. The following results were obtained: (1) In cutting two kinds of Al-Si alloys, namely the Al-2%Si alloy and Al-4%Si alloy, the progress of wear of the DLC/(Al,Cr)N-coated tool was slower than that of the DLC-coated tool. Therefore, the (Al,Cr)N interlayer was effective for decreasing the tool wear of the DLC-coated tool. (2) The wear progress of the two kinds of DLC-coated tools in cutting of Al-4%Si alloy was faster than that in cutting of Al-2%Si alloy. (3) In cutting of Al-2%Si alloy with the (Al,Cr)N/DLC-coated tool, the surface roughness was almost constant in the range of a cutting distance from 0.1 km to 9.5 km.

Effect of Friction Drilling on Metallurgical and Mechanical Properties of Composite Materials: A review

2020 ◽  
Vol 13 ◽  
Author(s):  
Mathew Alphonse ◽  
Bupesh Raja V.K ◽  
Palanikumar K.
Keyword(s):  
Mechanical Properties ◽  
High Speed ◽  
High Speed Steel ◽  
Single Step ◽  
Work Piece ◽  
Drilling Process ◽  
Drilling Tool ◽  
Sheet Metal Parts ◽  
Friction Drilling ◽  
Aisi H13

Abstract:: The objective of this study is to carry out a literature review on the effect of friction drilling parameters on the mechanical and metallurgical properties of materials. The friction drilling process uses heat generated by friction in between work piece and tool. In a single step tool penetrates into work material forming a circular hole and forms bushing without generating chips. Bushing acts as structural scaffold and guide to assemble sheet metal parts without need for separate threaded parts. This review focus on the basics of friction drilling, advantages, applications, metallurgical and mechanical properties of the tool and materials. Tools reviewed in this research are High speed steel (HSS) and AISI H13 chromium hot work steel. The study observes that coated friction drilling tool life is better than uncoated friction drilling tool. At higher spindle speed and feed rate good quality hole is produced with maximum bushing height and better surface finish.

Effect of plasma beam irradiation on the microstructure and phase composition of high-speed steel R6M5

2020 ◽  
Vol 62 (11) ◽  
pp. 1138-1142
Author(s):  
Bauyrzhan Rakhadilov ◽  
Sherzod Kurbanbekov ◽  
Мazhyn Skakov ◽  
Wojciech Wieleba ◽  
Laila Zhurerova
Keyword(s):  
Retained Austenite ◽  
High Speed ◽  
High Speed Steel ◽  
Volume Ratio ◽  
Steel Matrix ◽  
R6m5 Steel ◽  
Initial State ◽  
Long Distance ◽  
Plasma Beam ◽  
Α Phase

Abstract The present study is devoted to research into the morphology and structural-phase state of an R6M5 high speed steel surface layer after it was affected by a plasma beam. It was discovered, that R6M5 steel is a multi-phase material with an α-phase, γ-phase (retained austenite) and carbide phase just as in the initial state. The main phase component of the R6M5 steel matrix before and after plasma beam processing was an α-phase (γ → α’-martensite): lamellar and lath martensite; but lamellar martensite is dominated by a volume ratio ~90 % gross share α’-martensite. The γ-phase as the second morphological component of the steel matrix (retained austenite) yields within the martensite plates the form of twintype colonies with a volume ratio of ~6 %. It was established that there were М6С -type carbide particles of complex composition (Fe,W,Mo)6C in the material just as in the initial state. It should be said that in its initial state, the dislocation structure, formed under the effect of the plasma beam, is characterized by fairly high value of excess density of dislocations with an average value of ρ± = 2.0 × 1010 cm-2 (in the initial state ρ± = 1.7 × 1010 cm-2) along with scalar density. The depth of torsion curve of the face-centered space lattice in the α’-martensite is χ = 500 cm-1 (in the initial state it is equal to χ ~436 cm-1), the amplitude of the inner long-distance voltage is σ∂ = 280 МPа (in the initial state it is equal to σ∂ = 260 МPа). Thus, the amplitude of shift voltage is equal to σL = 420 МPа (in the initial state it is σL = 350 МPа); nevertheless, σL > σ∂ remains the mean torsion-curve of the fcs-lattice of α’-martensite maintaining its lamellar nature after the effect of the electron beam much as in the initial state.

scholarly journals Optimization Drilling Parameters of Aluminum Alloy Based on Taguchi Method

2019 ◽  
Vol 14 (2) ◽  
pp. 14-21
Author(s):  
Aseel Jameel Haleel
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Control Factors ◽  
Drilling Parameters ◽  
Tool Diameter ◽  
Twist Drills

This paper focuses on the optimization of drilling parameters by utilizing “Taguchi method” to obtain the minimum surface roughness. Nine drilling experiments were performed on Al 5050 alloy using high speed steel twist drills. Three drilling parameters (feed rates, cutting speeds, and cutting tools) were used as control factors, and L9 (33) “orthogonal array” was specified for the experimental trials. Signal to Noise (S/N) Ratio and “Analysis of Variance” (ANOVA) were utilized to set the optimum control factors which minimized the surface roughness. The results were tested with the aid of statistical software package MINITAB-17. After the experimental trails, the tool diameter was found as the most important factor that has effect on the surface roughness. The optimal drilling factors that minimized the surface roughness are (20mm/min cutting speed, 0.2 mm/rev feed rate, and 10mm tool diameter).

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