Investigation into Effect of Tool Wear on Drilling Force and Surface Finish While Dry Drilling Aluminum 2024

Abstract

Dry drilling of aluminum is environmentally friendly machining technique; in the meanwhile it is difficult to carry out due to aluminums gummy behavior and its tendency to adhere to cutting tools which diminishes hole quality. In spite of recent developments in cutting tool technology, HSS tools are still a cost effective choice due to relatively high toughness and feasibility to manufacture complex geometries of HSS drills besides its low price, make this tool a common choice for drilling soft materials such as aluminum. In this study effect of tool wear on thrust force and torque analyzed and hole quality assessed with respect to tool wear along tool life. Dry drilling on aluminum 2024, performed using HSS and HSCo drills at constant feed rate of 0.04 mm/rev and two cutting speeds of 28 and 94 m/min. Results revealed that the abrasive wear on flank face and BUE on chisel edge, margin and cutting lips were dominant mechanisms in all drills. It was found that with propagating the wear land on tool, thrust force and torque increased in both tools.

A New Approach to Modelling the Drilling Torque in Conventional and Ultrasonic Assisted Deep-Hole Drilling Processes

“…Aluminum alloys have been widely used in applications where materials with high strength-to-weight ratio are required, especially in the rapidly growing automobile and aerospace industries. Although these kinds of materials have good machinability in other cutting operations, they are also considered the most critical materials for drilling [1,2]. Drilling is a preferable machining process, as it takes about one-third of all manufacturing operations [3].…”