Hole quality and burr reduction in drilling aluminium sheets

Pilný, Lukáš; Chiffre, Leonardo De; Píška, Miroslav; Villumsen, Morten F.

doi:10.1016/j.cirpj.2012.03.005

Cited by 47 publications

(21 citation statements)

References 10 publications

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“…Prior to tapping, a total of 18 holes with a diameter of 5.1 mm as recommended by the tap manufacturer Drilling usually forms burrs on both the entry and exit side of the sheet as a result of plastic deformation. In some cases, small burrs below a certain height are allowed, but deburring operation after drilling is usually needed to avoid later burr-related problems (Peña et al, 2005;Pilný et al, 2012). For the ductile 6082 aluminium-silicon alloy large burrs were formed and therefore the predrilled holes were reamed by hand to an exact dimension with a smooth finish.…”

Section: Laboratory Tapping Testsmentioning

confidence: 99%

Improvements in the thread cutting torque for a6082-T6aluminum-based alloy with tapping tools utilizing diamond coating

Korhonen

Koistinen

Lappalainen

2018

Machining Science and Technology

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The use of thin film diamond as a hard tool coating offers a significant wear protection in numerous machining operations and increases considerably tool's lifetime. The extreme hardness of the diamond is especially needed in machining highly abrasive materials such as aluminium-silicon alloys.Tapping is widely used for thread fabrication and it is often a time consuming process causing a delay on an automated production line. This study investigated diamond coatings in thread cutting and the aim was to gain knowledge about the performance of diamond-coated taps. PVD diamond coatings were deposited using ultra short pulsed laser deposition (USPLD) techniques. Another type of nanodiamond coating was a chrome-nanodiamond (CND) coating deposited by a two-phase electrochemical process to produce a metal matrix with embedded detonation nanodiamond (DND) particles. The main points were the analysis of tool torques of the thread machining data, sticking of aluminium alloy and wear behavior and mechanism of tested tapping tools. The tested tools were analyzed by SEM regarding tool wear and sticking of aluminium on tool surface caused by mechanical interaction. Coating approaches turned out to provide 13-30% improvements in cutting and 37-51% improvements in reversing for overall mean torques compared to uncoated reference tools.

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Section: Laboratory Tapping Testsmentioning

confidence: 99%

Improvements in the thread cutting torque for a6082-T6aluminum-based alloy with tapping tools utilizing diamond coating

Korhonen

Koistinen

Lappalainen

2018

Machining Science and Technology

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“…To approach the optimum point efficiently, sequential experiments along the path of steepest ascent are performed. In equation (5), the largest coefficient is 0.018 for j 2 and the experimental step size vector (D) is defined as…”

Section: Optimization Of Major Design Parametersmentioning

confidence: 99%

Improvement of a deburring tool for intersecting holes with reduced irregular cutting of burr edge

Cho

Chae

Kim

2013

Proceedings of the Institution of Mechanical Engineers, Part B:

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A design optimization of deburring tools for intersecting holes is presented based on design of experiments and response surface methodology. A deburring tool with hemispherical cutter head mounted on a pivoted shaft was used to deburr intersecting holes easily and quickly. Due to the vibration of the tool during deburring, however, the surface of the deburred edge showed considerable irregularity. Tool dynamics was modeled with ADAMS software with the userdefined subroutines. Based on design of experiments and response surface methodology, the tool design was optimized with respect to tool vibration. Deburring tests with the optimized tool on Al6061-T6 specimens showed significant reduction in surface irregularity represented by an index value change from 1.3 to 0.7 mm.

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“…During the automatic drilling process of stacked metal plates, one of the most outstanding issues is the formation of interlayer burr [7,8]. The existence of interlayer burr not only affects the hole quality but also leads to connection decline or even failure [9]. Moreover, after completing the drilling process, the deburring operation has to be performed to eliminate the interlayer burrs.…”

Section: Introductionmentioning

confidence: 99%

Modeling and Optimization of Bidirectional Clamping Forces in Drilling of Stacked Aluminum Alloy Plates

et al. 2020

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Interlayer burrs formation during drilling of stacked plates is a common problem in the field of aircraft assembly. Burrs elimination requires extra deburring operations which is time-consuming and costly. An effective way to inhibit interlayer burrs is to reduce the interlayer gap by preloading clamping force. In this paper, based on the theory of plates and shells, a mathematical model of interlayer gap with bidirectional clamping forces was established. The relationship between the upper and lower clamping forces was investigated when the interlayer gap reaches zero. The optimization of the bidirectional clamping forces was performed to reduce the degree and non-uniformity of the deflections of the stacked plates. Then, the finite element simulation was conducted to verify the mathematical model. Finally, drilling experiments were carried out on 2024-T3 aluminum alloy stacked plates based on the dual-machine-based automatic drilling and riveting system. The experimental results show that the optimized bidirectional clamping forces can significantly reduce the burr heights. The work in this paper enables us to understand the effect of bidirectional clamping forces on the interlayer gap and paves the way for the practical application.

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Hole quality and burr reduction in drilling aluminium sheets

Cited by 47 publications

References 10 publications

Improvements in the thread cutting torque for a6082-T6aluminum-based alloy with tapping tools utilizing diamond coating

Improvements in the thread cutting torque for a6082-T6aluminum-based alloy with tapping tools utilizing diamond coating

Improvement of a deburring tool for intersecting holes with reduced irregular cutting of burr edge

Modeling and Optimization of Bidirectional Clamping Forces in Drilling of Stacked Aluminum Alloy Plates

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