Investigations into peck drilling process for large aspect ratio microholes in aluminum 6061-T6

Ravisubramanian, S.; Shunmugam, M.S.

doi:10.1080/10426914.2017.1376076

Cited by 16 publications

(10 citation statements)

References 32 publications

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“…Therefore, the relationship between the parameter and the cutting condition cannot be established as a binary linear-regression equation, and the quadratic or other regression models should be considered. Thus, the logarithmic polynomial regression given in (13) and polynomial regression given in (8) were both analyzed for the modeling of κ. The regression coefficients for model (13) are given in Table 4.…”

Section: Discussion a Effect Of Cutting Condition On Parameter κmentioning

confidence: 99%

“…However, the fact that the sensing of drilling forces by the surgeon is subjective [12] makes it difficult to control the pecking cycles. The thrust force and torque during peck drilling were observed to be lower than those during continuous drilling [13]. However, pecking cycle greatly reduces efficiency and increases the discomfort of the patient during the operation.…”

Section: Introductionmentioning

confidence: 90%

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Modified Chip-Evacuation Force Modeling and Chip-Clogging Prediction in Drilling of Cortical Bone

Zhang

Bian

et al. 2019

IEEE Access

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Chip clogging is one of the fundamental issues faced by the dentists during the drilling of cortical bone. The chip clogging can lead to significant increase in temperature, thrust force and torque, and can even cause the drill bit to break. In this study, a modified chip-evacuation model to estimate the thrust force was developed for drilling of the cortical bone. First, the modified chip-evacuation force model with two parameters was developed based on the flute geometry. A set of drilling tests was conducted to calibrate the model parameters. Secondly, the parameter models were established as functions of spindle speed and feed, and the coefficients were then determined through nonlinear-regression analysis. The importance of cutting parameters on the model parameters was investigated via analysis of variance. Thirdly, the validity of the force model was analyzed by experimental results. Subsequently, based on the gradient of the chip-evacuation force, the chip-clogging prediction was conducted, and the prediction accuracy was assessed by the validation tests. Finally, the effect of cutting condition on the chip clogging was explored. The modified chip-evacuation force model proved to be an effective tool for predicting the thrust force, and the chip clogging could be estimated accurately with a relative error less than 10%. The spindle speed and the feed both had significant effects on the chip-evacuation force and chip clogging. The modified model could provide a better approach to finding how a pecking cycle can be implemented, and then, it can assist surgeons in selecting cutting conditions. INDEX TERMSChip clogging, chip-evacuation force, drilling of cortical bone, twist drill. NOMENCLATURE F z Chip-evacuation force. F z (0) Initial cutting force. λ Ratio between the lateral and axial pressure. D Drill diameter. A 0 Half flute area. µ f Coefficient of friction between the chip and the flute. µ w Coefficient of friction between the chip and the hole wall. l f Effective contact length of the chip element with the flute face. l h Effective contact length of the chip element with the flute heel. The associate editor coordinating the review of this manuscript and approving it for publication was Ming Luo .l w Effective contact length of the chip element with the hole wall. θ Angle between the flute face and the plane formed across the flute. z Dimensionless depth. z Hole depth. P Pressure intensity along the chip flow direction. κ, ξ Parameters of the chip-evacuation force model. F model Fitting value of the chip-evacuation force from the force model. F exp Processed thrust force from the drilling experiment. α 0 , α 1 , α 2 , α 3 Regression coefficients of κ model from the polynomial regression. α 0 , α 1 , α 2 , α 3 Regression coefficients of κ model from the logarithmic polynomial regression.

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Section: Discussion a Effect Of Cutting Condition On Parameter κmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 90%

Modified Chip-Evacuation Force Modeling and Chip-Clogging Prediction in Drilling of Cortical Bone

Zhang

Bian

et al. 2019

IEEE Access

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“…At the deeper drilled depth, the increased amount of chips fill up the flutes, leading to chip-clogging, which causes the total torque to increase exponentially [6][7][8][9][10][11]. The addition of such a chip evacuation torque results in excessive torsional stress, leading to a common failure of the tools known as drill breakage [8,11,12]. Whenever the drill broke inside the drilled hole, it was difficult to take out the broken part of the tool from the workpiece, causing catastrophic damage to the parts as well as considerable economic lost [13].…”

Section: Introductionmentioning

confidence: 99%

“…Consequently, chip evacuation has become the main constrain of deep drilling [14]. Specialized drilling tools and techniques have been developed for deep hole drilling, such as the single-lip gun drill, double-tube and single tube drill, boring and trepanning association [15], groove-type chip breaker [16], and peck drilling [12]. Nevertheless, twist drills are still used as a dominant tool, as much as 75% of the drilling operations in the deep hole drilling industry because of their low cost, versatility, and flexibility [17].…”

Section: Introductionmentioning

confidence: 99%

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

Chu

Nguyen²,

Ngo

et al. 2018

Applied Sciences

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This paper presents a new approach to developing the torque model in deep hole drilling, both for conventional and ultrasonic assisted drilling processes. The model was proposed as a sum of three components: the cutting, the chip evacuation and the stick-slip torques. Parameters of the new model were carried out by applying the regression analysis technique, with the correlation values higher than 0.999. The data were collected from 36 experimental dry drilling tests, both in conventional and ultrasonic assisted cutting conditions, with the depth-to-diameter of the drilled holes of 7.5. The major advantage of the new model compared to previous models is that the new model of chip-evacuation torque has only one coefficient, thus making it easier to evaluate and compare different deep-drilling processes. The effectiveness of ultrasonic assistance in deep hole drilling was also highlighted using the proposed model. The new model is promising to predict critical depth and torque in deep hole drilling.

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“…the jamming of chips inside the flute. The addition of chip evacuation torque results in excessive torsional stress, and once the maximum torsional strength of the drill is reached, drill breakage would occur (Mellinger et al, 2002), (Ravisubramanian & Shunmugam, 2017), (Furnesset al, 1996). (Amini et al, 2013)… which can be taken from Ultrasonic Assisted Drilling (UAD).…”

Section: Introductionmentioning

confidence: 99%

The Multi-Response Optimization of Machining Parameters in the Ultrasonic Assisted Deep-Hole Drilling Using Grey-Based Taguchi Method

Chu¹,

Tjprc²

2018

IJMPERD

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This paper presents a practical approach for the multiple response optimizations of operational parameters in the ultrasonic assisted drilling of deep holes. Applying the Taguchi design of experiments, a plan of 27 drilling tests on 6061 aluminium alloy with the depth-to-diameter ratio of 10 was conducted. The responses of cutting force and torque, maximum force and torque, including the chip-evacuation parts which appeared when drilling deep holes, were chosen to be optimized. Three significant drilling parameters, named vibration amplitude, feeding rate and cutting speed were found to have the most significant effects on the output responses. Based on the grey relational grade analysis and analysis of variance technique, optimum levels as well as the percentage contribution of such parameters were identified. Confirmation test was conducted to validate the test result. Experimental results showed that the multi-response optimization problem in ultrasonic assisted the deep hole drilling can be effectively addressed through the combination of Taguchi design and Grey relational analysis.

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Investigations into peck drilling process for large aspect ratio microholes in aluminum 6061-T6

Cited by 16 publications

References 32 publications

Modified Chip-Evacuation Force Modeling and Chip-Clogging Prediction in Drilling of Cortical Bone

Modified Chip-Evacuation Force Modeling and Chip-Clogging Prediction in Drilling of Cortical Bone

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

The Multi-Response Optimization of Machining Parameters in the Ultrasonic Assisted Deep-Hole Drilling Using Grey-Based Taguchi Method

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