Hole-making processes and their impacts on the microstructure and fatigue response of aircraft alloys

Sun, Dan; Lemoine, P.; Doyle, Patrick; Malinov, Savko; Zhao, Qian; Qin, Xuda; Jin, Yan

doi:10.1007/s00170-016-9850-3

Cited by 66 publications

(41 citation statements)

References 34 publications

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“…Surface roughness is mostly used as an index to determine the surface finish and, consequently, workpiece quality in machining processes [67][68]. Besides, it is an important requirement to evaluate machined surfaces, affecting lubrication, friction, corrosion resistance, fatigue resistance, and other mechanical properties [69][70][71]. The average surface roughness, Ra, and the average maximum height of the profile, Rz, were evaluated in the borehole surfaces of AISI H13 hardened steel obtained through helical milling.…”

Section: Roughness On Helical Milling Of Aisi H13 Hardened Steelmentioning

confidence: 99%

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Pereira

Silva

Lauro

et al. 2019

Applied Soft Computing

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Helical milling is a hole-making process which has been applied in hardened materials. Due to the difficulties on achieving high-quality boreholes in these materials, the influence of noise factors, and multi-quality performance outcomes, this work aims the multi-objective robust design of hole quality on AISI H13 hardened steel. Experiments were carried out through a central composite design considering process and noise factors. The process factors were the axial and tangential feed per tooth of the helix, and the cutting velocity. The noise factors considered were the tool overhang length, the material hardness and the borehole height of measurement. Response models were obtained through response surface methodology for roughness and roundness outcomes. The models presented good explanation of data variability and good prediction capability. Mean and variance models were derived through robust parameter design for all responses. Similarity analysis through cluster analysis was realised, and average surface roughness and total roundness were selected to multi-objective optimisation. Mean square error optimisation was performed to achieve bias and variance minimization. Multi-objective optimisation through normalized normal constraint was performed to achieve a robust Pareto set for the hole quality outcomes. The normalized normal constraint optimisation results outperformed the results of other methods in terms of evenness of the Pareto solutions and number of Pareto optimal solutions. The most compromise solution was selected considering the lowest Euclidian distance to the utopia point in the normalized space. Individual and moving range control charts were used to confirm the robustness achievement with regard to noise factors in the most compromise Pareto optimal solution. The methodology applied for robust modelling and optimisation of helical milling of AISI H13 hardened steel was confirmed and may be applied to other manufacturing processes. KeywordsHelical milling; AISI H13 hardened steel; Multi-objective robust optimization; Robust parameter design; Normalized normal constraint method. R 2 coefficient of determinationRadj 2 adjusted coefficient of determination Radj 2 prediction coefficient of determination

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Section: Roughness On Helical Milling Of Aisi H13 Hardened Steelmentioning

confidence: 99%

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Pereira

Silva

Lauro

et al. 2019

Applied Soft Computing

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“…This is because aircrafts constantly operate under vibration/shock conditions where thousands of fastener holes in the fuselage skins are prone to fatigue [2]. Fatigue cracks normally initiate and propagate after the fastened holes create regions of concentrated stress; therefore, the reliability of aircraft structures depends on their fatigue life, which is directly related to hole quality [3]. In addition, the drilling process is normally amongst the last steps of final assembly of fabricating parts, where poor hole quality might lead to part rejection, which can become costly if optimum process parameters, tools, or drilling operations are not taken into consideration [4].…”

Section: Introductionmentioning

confidence: 99%

Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach

Aamir

Tolouei‐Rad

et al. 2020

Materials

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In industries such as aerospace and automotive, drilling many holes is commonly required to assemble different structures where machined holes need to comply with tight geometric tolerances. Multi-spindle drilling using a poly-drill head is an industrial hole-making approach that allows drilling several holes simultaneously. Optimizing process parameters also improves machining processes. This work focuses on the optimization of drilling parameters and two drilling processes—namely, one-shot drilling and multi-hole drilling—using the Taguchi method. Analysis of variance and regression analysis was implemented to indicate the significance of drilling parameters and their impact on the measured responses i.e., surface roughness and hole size. From the Taguchi optimization, optimal drilling parameters were found to occur at a low cutting speed and feed rate using a poly-drill head. Furthermore, a fuzzy logic approach was employed to predict the surface roughness and hole size. It was found that the fuzzy measured values were in good agreement with the experimental values; therefore, the developed models can be effectively used to predict the surface roughness and hole size in multi-hole drilling. Moreover, confirmation tests were performed to validate that the Taguchi optimized levels and fuzzy developed models effectively represent the surface roughness and hole size.

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“…Using design of experiment methods, such as Taguchi and response surface, showed that feed rate and cutting speed are the most influential parameters on the drilling of steels. Different machining methods, such as ultrasonic drilling, and tool selection leads to better surface quality and drilling of soft materials, such as Al, and helical milling increases fatigue life [ 18 , 19 , 20 ]. The effect of pre-hole drilling on Al 6061-7075 with uncoated HSS drills showed that pre-holes reduce cutting force and improve surface roughness and chip generation [ 21 ].…”

Section: Introductionmentioning

confidence: 99%

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

2018

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Drilling is one of the most useful metal cutting processes and is used in various applications, such as aerospace, electronics, and automotive. In traditional drilling methods, the thrust force, torque, tolerance, and tribology (surface roughness) are related to the cutting condition and tool geometry. In this paper, the effects of a pre-center drill hole, tool material, and drilling strategy (including continuous and non-continuous feed) on thrust force, surface roughness, and dimensional accuracy (cylindricity) have been investigated. The results show that using pre-center drill holes leads to a reduction of the engagement force and an improvement in the surface quality and cylindricity. Non-continuous drilling reduces the average thrust force and cylindricity value, and High Speed Steels HSS-Mo (high steel speed + 5–8% Mo) reduces the maximum quantity of cutting forces. Moreover, cylindricity is directly related to cutting temperature and is improved by using a non-continuous drilling strategy.

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Hole-making processes and their impacts on the microstructure and fatigue response of aircraft alloys

Cited by 66 publications

References 34 publications

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

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