Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

Habib, Numan; Sharif, Aamer; Hussain, Aquib; Aamir, Muhammad; Giasin, Khaled; Pimenov, Danil Yurievich; Ali, Umair

doi:10.3390/met11060891

Cited by 30 publications

(19 citation statements)

References 38 publications

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“…The resulting surface roughness is influenced by the mechanical properties of the machined material, the geometry of the tool and its wear, the magnitude of the cutting forces and the stability of the process, the cutting environment and, last but not least, the cutting conditions. In the case of drilling, the feed rate should have the highest effect, followed by the cutting speed [4,17,18,36]. Drilling is a relatively specific machining process, and the depth of drilling also plays a role in the quality of the surface.…”

Section: Surface Roughnessmentioning

confidence: 99%

Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel

et al. 2021

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Dry machining is one of the main ways to reduce the environmental burden of the machining process and reduce the negative effect of the cutting fluid and aerosols on operators. In addition, dry machining can reduce overall machining costs and, in the case of large workpieces, reduce the extra work associated with removing residual cutting fluid from the workpiece and adjacent area. For high-strength structural steel products, it is typical to drill holes with larger diameters of around 20 mm. Therefore, this work is devoted to the investigation of the dry drilling process carried out on a workpiece made of S960QL steel with a helical drill with a diameter of 21 mm. The aim was to find suitable cutting conditions for dry drilling with regard to process stability and workpiece quality. An experiment performed with a coolant served as a comparison base. A dry drilling experiment was performed with cutting speeds from 30 to 70 m·min−1 and feeds from 0.1 to 0.3 mm·rev−1, and with the results of this experiment, the same experiment with flood cooling was performed. During the drilling process, spindle torque values were recorded using the indirect spindle current recording method. The macroscopic chip morphology was studied to understand the cutting process. The chip thickness ratio was measured, as well as the maximum diameter of spiral chips. On the final workpiece, the qualitative and dimensional parameters of the holes were evaluated, such as the diameter, cylindricity and surface roughness, depending on the change in the cutting conditions and cutting environment. Evaluation of the obtained data led to the following conclusions. When drilling the S960QL material, there is only a very small increase in the drilling torque during dry drilling compared to drilling with cutting fluid. The increase in friction demonstrated by the chip thickness coefficient is significant. The influence of the environment on the dimensional accuracy showed a tendency for a slight increase in the holes’ diameters during dry machining. In comparison, the cylindricity of the dry-drilled holes shows a lower deviation than the holes drilled with cutting fluid. The surface roughness of the holes after dry drilling is affected by the increased friction of the outgoing chips, despite the resulting parameters being very good due to the drilling technology standards. This work provides a comprehensive view of the dry drilling process under defined conditions, and the results represent suitable cutting conditions to achieve a stable cutting process and a suitable quality of drilled holes.

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Section: Surface Roughnessmentioning

confidence: 99%

Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel

et al. 2021

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“…Due to its high strength-to-weight ratio, the 7xxx series of aluminum alloys are the preferred choice in aircraft, space, and military industries [ 20 ]. One of the most commonly used members of this series is the aluminum alloy AA7075 [ 21 ]. However, despite the high strength-to-weight ratio and better fatigue properties, the applications of AA7075 are limited because of its low wear resistance, fair tribological properties, average machinability, and higher cost [ 22 ].…”

Section: Introductionmentioning

confidence: 99%

Investigating the Microstructural and Mechanical Properties of Novel Ternary Reinforced AA7075 Hybrid Metal Matrix Composite

et al. 2022

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This study investigates the comparison of the microstructural and mechanical properties of a novel ternary reinforced AA7075 hybrid metal matrix composite. Four samples, including AA7075 (base alloy), AA7075-5wt %SiC (MMC), AA7075-5wt %SiC-3wt %RHA (s-HMMC), and AA7075-5wt %SiC-3wt %RHA-1wt %CES (n-HMMC) were developed using the stir casting liquid metallurgy route, followed by the heat treatment. The experimental densities corresponded with the theoretical values, confirming the successful fabrication of the samples. A minimum density of 2714 kg/m3 was recorded for the n-HMMC. In addition, the highest porosity of 3.11% was found for n-HMMC. Furthermore, an increase of 24.4% in ultimate tensile strength and 32.8% in hardness of the n-HMMC was recorded compared to the base alloy. However, its ductility and impact strength was compromised with the lower values of 5.98% and 1.5 J, respectively. This was confirmed by microstructural analysis, which reveals that n-HMMC has mixing issues and forms agglomerates in the matrix, which served as the potential sites of stress concentration leading to low impact strength and ductility. Nevertheless, the hybrid composites showed superior mechanical properties over the MMC and its base alloy.

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“…The machining process has been an essential part of the industry since the industrial revolution [1,2]. Milling is a broadly used machining process in various manufacturing industries [3].…”

Section: Introductionmentioning

confidence: 99%

Machining of Carbon Steel under Aqueous Environment: Investigations into Some Performance Measures

et al. 2022

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In this study, a new machining approach (aqueous machining) is applied for mill machining and its performance is compared with traditional wet machining. AISI 1020 steel is employed as the test material and Taguchi statistical methodology is implemented to analyze and compare the performance of the two machining approaches. The cutting speed, feed rate, and depth of cut were the machining parameters used for both types of machining, while the selected response variables were surface roughness and hardness. Temperature variations were also recorded in aqueous machining. Compared with wet machining, aqueous machining resulted in lower surface roughness (up to 13%) for the same operating conditions and about 14% to 16% enhancement in hardness due to the formation of finer pearlite, as revealed by the microstructure analysis. Compared to the parent unmachined surface, the hardness of machined surfaces was 24% to 31% higher in wet machining and 44% to 51% higher in aqueous machining. Another benefit of aqueous machining was the energy gain, which ranged from 718 to 8615.96 J. This amount of heat energy can be used as waste heat for preheating domestic hot water, running the organic Rankine cycle with waste heat and preheating the inlet saline water for desalination, vacuum desalination, etc. If successfully implemented in the future, this idea will provide a step towards achieving sustainable machining by saving lubricants and toxic wastes in addition to saving energy for secondary applications.

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Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

Cited by 30 publications

References 38 publications

Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel

Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel

Investigating the Microstructural and Mechanical Properties of Novel Ternary Reinforced AA7075 Hybrid Metal Matrix Composite

Machining of Carbon Steel under Aqueous Environment: Investigations into Some Performance Measures

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