Performance Analysis of Multi-Spindle Drilling of Al2024 with TiN and TiCN Coated Drills Using Experimental and Artificial Neural Networks Technique

Aamir, Muhammad; Tolouei‐Rad, Majid; Vafadar, Ana; Raja, Muhammad Nouman Amjad; Giasin, Khaled

doi:10.3390/app10238633

Cited by 25 publications

(21 citation statements)

References 56 publications

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“…Tool wear, chip formation, and hole quality are key parameters of the drilling process and are strongly influenced by spindle speed (n), feed rate (f ), tool geometry, machine tool setup, and cutting conditions such as wet/dry or other environmental factors [8][9][10][11][12]. In contrast to wet machining, dry drilling is preferable to reduce the environmental impact of coolants and eliminate the costs of cutting fluids [13].…”

Section: Introductionmentioning

confidence: 99%

Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Aamir

Giasin

Tolouei‐Rad

et al. 2021

Metals

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Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

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Section: Introductionmentioning

confidence: 99%

Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Aamir

Giasin

Tolouei‐Rad

et al. 2021

Metals

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“…A manual milling machine model (5KS, 5KV) that has a maximum spindle speed of 3450 rpm was used for the drilling operations, and a SUNHER poly-drill head type, MH30/13, was used for the multi-hole simultaneous drilling process. Spindle speeds of 1007, 2015, and 3025 rpm and feeds of 0.04, 0.08, and 0.14 mm/rev were selected based on the limitations of the available manual milling machine and previous literature on drilling aluminium alloys in the multi-spindle drilling process [16][17][18][19][20]. All the drilling experiments were conducted under dry conditions due to environmental concerns and the cost associated with the cutting fluid and its disposal [21,22].…”

Section: Methodsmentioning

confidence: 99%

Evaluation of the Surface Defects and Dimensional Tolerances in Multi-Hole Drilling of AA5083, AA6061, and AA2024

et al. 2021

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Drilling is one of the most performed machining operations for riveting and assembly operations in many industrial sectors. The accuracy of the drilled holes and their surface finish play a vital role in the longevity and performance of the machined components, which, in turn, increase productivity. Therefore, this study investigated the effect of the multi-spindle drilling process on dimensional hole tolerances, such as hole size, circularity, cylindricity, and perpendicularity. In addition, the surface defects formed in the holes were examined using scanning electron microscopy. Three aluminium alloys, AA2024, AA6061, and AA5083, which are commonly used in the aerospace, automotive, and marine sectors, were chosen as the study materials. The results showed that the holes drilled in AA2024 gave less circularity error, cylindricity error, and perpendicularity error. In the case of hole size, the holes drilled in AA6061 were less deviated from the nominal size following holes drilled in AA2024 and AA5083 alloys. Surface damage in the form of metal debris adhesion, smeared material, side flow, and feed marks was found on the inner hole surface. Holes drilled in AA5083 alloy had the worst surface finish and were the most oversized, which was associated with noticeable damage and deformations in their inner surface. The ANOVA results revealed that the spindle speed was more influential than feed and mainly affected the hole size and cylindricity errors. However, in the case of circularity error and perpendicularity error, drilling parameters were found to be insignificant.

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“…Aluminium and its alloys are very attractive to many manufacturing industries due to its unique combinations of properties with outstanding engineering applications across various industries [16,17]. Aluminium has low density, reasonably high strength, high ductility, high thermal and electrical conductivities, good oxidation and corrosion resistance, easy to manufacture and has a relatively low cost [18].…”

Section: Aluminium Alloysmentioning

confidence: 99%

Analysis of the Performance of Drilling Operations for Improving Productivity

Tolouei‐Rad¹,

Aamir²

2021

Drilling Technology

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Drilling is a vital machining process for many industries. Automotive and aerospace industries are among those industries which produce millions of holes where productivity, quality, and precision of drilled holes plays a vital role in their success. Therefore, a proper selection of machine tools and equipment, cutting tools and parameters is detrimental in achieving the required dimensional accuracy and surface roughness. This subsequently helps industries achieving success and improving the service life of their products. This chapter provides an introduction to the drilling process in manufacturing industries which helps improve the quality and productivity of drilling operations on metallic materials. It explains the advantages of using multi-spindle heads to improve the productivity and quality of drilled holes. An analysis of the holes produced by a multi-spindle head on aluminum alloys Al2024, Al6061, and Al5083 is presented in comparison to traditional single shot drilling. Also the effects of using uncoated carbide and high speed steel tools for producing high-quality holes in the formation of built-up edges and burrs are investigated and discussed.

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Performance Analysis of Multi-Spindle Drilling of Al2024 with TiN and TiCN Coated Drills Using Experimental and Artificial Neural Networks Technique

Cited by 25 publications

References 56 publications

Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Evaluation of the Surface Defects and Dimensional Tolerances in Multi-Hole Drilling of AA5083, AA6061, and AA2024

Analysis of the Performance of Drilling Operations for Improving Productivity

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