Numerical Simulation and Experimental Study on the Drilling Process of 7075-t6 Aerospace Aluminum Alloy

Luo, Haitao; Fu, Jia; Tang, Wu; Chen, Ning; Li, Huadong

doi:10.3390/ma14030553

Cited by 20 publications

(13 citation statements)

References 30 publications

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“…As currently seen, F was the most significant boundary. (Al-Tameemi et al 2021); (Luo et al 2021) During machining of aluminum the burr is formed at a high rate, and it affects the surface of the material, (Grzesik 2016) which is the limitation of this research. The surface finish can be better if changing the parameters and tool in AA 6020 is studied and will be developed in future (Liu et al 2020).ays of supportability (monetary,natural and social).…”

Section: Discussionmentioning

confidence: 95%

Novel improvement of surface roughness for AA6020 using AlTiN coated HSS tool in comparison with uncoated HSS tool using surface roughness tester.

2022

pnr

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Aim:The Main motive of this research is to detect surface roughness using surface roughness tester and analyse the enhancement of surface roughness for AA6020 using AlTiN coated HSS tool and compare the results with uncoated HSS tool. Materials and Methods: In this investigation, AA6020 of length 20mm and diameter 25mm is used. There are 2 groups in this research, the experimental group which is the AA6020 samples drilled with AlTiN coated HSS tool and control group which is the AA6020 samples drilled with uncoated HSS tool. According to the calculation of G power, the sample size is derived to be 20 per group which makes the total sample size to be 40. The surface roughness test is carried out according to the ASTM standards.Results: An analysis of the results of surface roughness, it is observed that the average surface roughness for experimental group(AA6020 drilled with AlTiN coated HSS drill) is 1.36065μm. and for control group(AA6020 drilled with uncoated HSS drill) is 2.05065μm . On comparison of the results using ANOVA test f/or both the groups, it is noted that there is a significant decrease in surface roughness in the experimental group with significance level of 0.00 (P<0.05). Conclusion: Within the limitations of this study, we can conclude that AA6020 drilled with AlTiN coated HSS drill gives better results for surface roughness than AA6020 drilled with uncoated HSS drill.

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Section: Discussionmentioning

confidence: 95%

Novel improvement of surface roughness for AA6020 using AlTiN coated HSS tool in comparison with uncoated HSS tool using surface roughness tester.

2022

pnr

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“…Adaptive meshing is a remesh technique in which an old deformed mesh is replaced with a new one. Smoothing shifts nodes to produce more standard element configurations, whereas refinement enhances the density of mesh by decreasing the size of mesh [31,32]. Adaptive meshing enhances simulation accuracy.…”

Section: Materials Selection and Methodologymentioning

confidence: 99%

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Senthilkumar

Hariharan

Tamizharasan

et al. 2022

Advances in Materials Science and Engineering

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In this present work, finite element analysis (FEA)-based simulation of end-milling of AISI1045 steel using tungsten carbide tool was performed using DEFORM-3D simulation software. Usui tool wear model, Johnson-cook material model and adaptive remeshing are considered during machining simulation. The impact of machining variables rate of feed, tool speed, and depth of cut was investigated, and the best integration of variables was distinguished for lower cutting temperature, principal stress, cutting forces, effective stresses, tool wear, and effective strain. The obtained results were correlated using experimentation in a vertical machining center attached with a Kistler tool dynamometer with data acquisition setup for capturing the cutting forces, and an infrared (IR) thermometer was used to measure the cutting temperature, and a comparison was done. Results showed a good correlation. There is a relationship between experimental and numerical results, and simulation findings can be utilised for interpreting the influence of machining parameters.

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“…Based on the experimental results, the drilling process was modeled for 7075-T6 alloy and feed rate of 0.1 mm/rev and 1520 rpm, considering that T6 alloy gives the most optimum and effective results. There are modeling studies for 7075-T6 alloy using different Johnson-Cook material models in the literature [52,53]. In this study, the tabular data format containing strain, strain rate and temperature measurements with a larger scale measured separately was used.…”

Section: D Fe Model Of the Drilling Processmentioning

confidence: 99%

Comparative Analysis in Drilling Performance of AA7075 in Different Temper Conditions

Yarar

Ertürk

Koç

et al. 2022

J. of Materi Eng and Perform

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The main objective of this study is to examine the machinability and the surface quality conditions of the AA7075 material with different temper conditions. For this purpose, various temper treatments are implemented to evaluate the impact of microstructural properties on tool wear and the surface quality of the drilled holes. The drilling operations have been done on 0, F, T4, T6, and T7 temper conditions. Process parameters were three different spindle speeds (715, 1520, and 3030 rev/min) and three feed rates (0.1, 0.2, and 0.3 mm/rev) with HSS-G highperformance ground standard twist drill bit. The present work deals with the effects of temper conditions on thrust force, drilling temperature, tool wear, surface integrity, and chip morphology. Response surface methodology was used in the evaluation of experiment results. The optimization results showed that while thrust force and torque are not significantly affected by a change in spindle speed, they are sensitive to an increase in feed rate. Heat-generation on the drill bit is the lowest at low levels of both the feed rate and spindle speed parameters. The AA7075-T6 condition specimen was machined with continuous chip formation, resulting in the best hole surface quality. The 3D finite element modeling of the drilling process was carried out, and the drilling performance of AA7075-T6 was evaluated in terms of thrust force, heat generation, and chip formation.

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Numerical Simulation and Experimental Study on the Drilling Process of 7075-t6 Aerospace Aluminum Alloy

Cited by 20 publications

References 30 publications

Novel improvement of surface roughness for AA6020 using AlTiN coated HSS tool in comparison with uncoated HSS tool using surface roughness tester.

Novel improvement of surface roughness for AA6020 using AlTiN coated HSS tool in comparison with uncoated HSS tool using surface roughness tester.

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Comparative Analysis in Drilling Performance of AA7075 in Different Temper Conditions

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