On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling Method

Abstract

The current study presents three calibration approaches for the hole-drilling method (HDM). A total of 72 finite element models and 144 simulations were established to calibrate the measurements of the strain sensors. The first approach assumed the stresses acted on the boundaries of the drilled hole and thus analyzed the surrounding displacements field. The second analysis considered the loads on the outer surfaces of the specimen while measuring the strains’ differences between the model with and without the drilled hole. The third approach was more comprehensive as it considered the mechanical and thermal effects of the drilling operations. The proposed approaches were applied to two different materials (AISI 1045 and CFRP). The steel specimens were machined using a CNC lathe while the composite laminates were manufactured using the robotic fiber placement (RFP) process. Subsequently, the residual stresses (RSs) were measured using the HDM. The obtained data were compared with X-ray diffraction measurements for validation. The results showed better estimation of the RSs when utilizing the third approach and clear underestimation of the stresses using the second approach. A divergence in RSs values between the three approaches was also detected when measuring the stresses in the internal layers of the composite laminates.

Experimental Analysis of Effect of Machined Material on Cutting Forces during Drilling

“…The novelty of our research work lies in the complexity and scope of the considered explanatory variables. Above all, in that, unlike other publications [ 37 , 38 , 39 , 40 , 41 , 42 , 43 ], we also consider such tool factors (point angle—ε r , lip relief/clearance angle—α o , and helix angle—ω r ) that meet the condition of mutual independence and the condition of orthogonality with respect to the DOE methodology. This article provides an adequate combination of experimental, numerical, and analytical approaches for hole drilling simulation.…”

“…Storchak et al [ 39 ] dealt with the numerical modelling of drilling short holes in AISI 1045 material, and FEM and DOE were applied. Size effects during the micro drilling of carbon steel C45 are predicted by a 3D multiphase FE model in [ 41 ], and incremental hole drilling (AISI 1045 and CFRP) is modelled by FEM in [ 42 ]. In addition to these studies, the Deform 3D software is frequently used to simulate drilling operations in the literature [ 43 , 44 , 45 ], e.g., in [ 41 ], carbon steel AISI 1050 (DIN 1.1210) is the experimental material for the FE simulation of the drilling process, and drill stresses are analyzed by the Deform-3D.…”

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

“…These positive residual stresses enhance the overall compressive strength of mining drill bits, particularly against cyclic loading and bending loads, thereby improving their fatigue resistance. However, it is important to note that excessive residual stresses, whether tensile or compressive, can lead to deformation and cracking, thereby reducing the performance and longevity of the drilling bits [80,81]. This ensures that they have the mechanical qualities required for reliable performance in compression-dominated and cyclic loading situations common in mining applications.…”

Critical Analysis of the Current Trends in Ensuring the Holes Quality when Drilling CFRP/Titanium Alloy Stacks

“…У ранніх дослідженнях була запропонована кількісна оцінка характерних пошкоджень поверхні отвору як у шарі ВПКМ, так і в металевому шарі. Збільшення коефіцієнта розшарування зменшує навантаження на розтяг і збільшує залишкові напруження у шарі матеріалу [10]. У найзагальнішому випадку параметри якості отворів можна розділити на: геометричну точність і точність форми, зокрема, діаметр отвору, відхилення від круглості і циліндричності та параметри морфології оброблених поверхонь.…”