Quantitative analysis of chip extraction in drilling of Ti6Al4V

Brinksmeier, E.; Pecat, Oliver; Rentsch, R.

doi:10.1016/j.cirp.2015.04.064

Cited by 31 publications

(11 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The maximum drilled number of holes reached was 10 for A m = 0.1 mm, which was doubled for A m = 0.25 mm, before the observation of tool-chips welding process as shown in Figure 4B,C. Increasing the number of holes drilled with higher amplitude can be attributed to the lower thermal load, small chip radian, and enhanced evacuation efficiency [38,40,41,43]. Digital Microscope, the hole diameter error was calculated by taking an average of ten points on the top and bottom surfaces for both materials using a Mitutoyo Coordinate Measuring Machine (CMM).…”

Section: Effect Of Tool Wear On the Thrust Forcementioning

confidence: 90%

“…For f = 0.025 mm/rev, the utilization of LF-VAD resulted in up to 40% reduction in the thermal load compared to CD. This reduction could be attributed to (a) the significant change of the Ti6Al4V chip morphology from a continuous spiral shape for CD to a segmented one [38,40], (b) the enhanced chip evacuation efficiency due to the tool axial oscillation mechanism [38,40,43], and (c) the cyclic cooling interval during the interrupted cutting process [40]. Moreover, increasing the modulation amplitude for VAD resulted in a lower tool tip temperature.…”

Section: Effect Of Tool Wear On the Thrust Forcementioning

confidence: 99%

“…Advanced machining process such as vibration-assisted drilling (VAD) where the axial feed is superimposed by a harmonic motion [38,39], can be seen as a promising candidate to attain better machining quality. This is possibly due to the significant benefit of changing the chip morphology from continuous to segmented [40][41][42] and the efficient chip evacuation mechanism [40,43].The experimental investigation of low-frequency vibration-assisted drilling (LF-VAD) of CFRP/Ti6Al4V showed promising results compared to the conventional drilling (CD) [38,44]. The utilization of 1.5 cycle/rev frequency with minimum quantity lubrication (MQL) resulted in a 43% reduction in the cutting temperature with improved surface integrity [44].…”

mentioning

confidence: 99%

See 2 more Smart Citations

An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

Hussein

Sadek

Elbestawi

et al. 2019

JMMP

View full text Add to dashboard Cite

The use of lightweight material such as CFRP/Ti6Al4V in stacked structures in the aerospace industry is associated with improved physical and mechanical characteristics. The drilling process of nonuniform structures plays a significant role prior to the assembly operation. However, this drilling process is typically associated with unacceptable CFRP delamination, hole accuracy, and high tool wear. These machining difficulties are attributed to high thermal load and poor chip evacuation mechanism. Low-frequency vibration-assisted drilling (LF-VAD) is an advanced manufacturing technique where the dynamic change of the uncut chip thickness is used to manipulate the cutting energy. An efficient chip evacuation mechanism was achieved through axial tool oscillation. This study investigates the effect of vibration-assisted drilling machining parameters on tool wear mechanisms. The paper also presents the effect of tool wear progression on drilled hole quality. Hole quality is described by CFRP entry and exit delamination and hole accuracy. The results showed a significant reduction in the thrust force, cutting torque, cutting temperature, and flank wear-land.This wear mechanism was attributed to hard and soft abrasion modes [14]. The hard mode is located at WC grains due to the generated dynamic stresses from the broken fiber, material reinforcement, and powder like chips [15]. Consequently, the WC grains suffer crack initiation and propagation fracture [16]. On the other hand, the relatively low hardness Co binder is more easily damaged by carbon fibers (CF) in a process known as soft abrasion mode [14,17,18]. Hence, WC grain spalling is more rapid under the cyclic machining load.High cutting temperature, poor chip evacuation mechanism, and burr formation are of the common issue during the drilling process of Ti6Al4V [19][20][21]. These problems resulted in a higher probability of flute-chip accumulation, progressive tool wear, and poor surface integrity [19,20,22]. Low thermal conductivity and high chemical affinity to the majority of tool materials are due to the adverse titanium characteristics, which resulted in a significant reduction in the tool life with a high probability of catastrophic failure [20,23,24]. This effect contributed to the cutting stress concentration on the tool cutting edge where the maximum cutting temperature is located. Therefore, the machining process of Ti6Al4V is typically associated with the formation of built-up-edge (BUE). The formation of BUE has a significant drawback on the machined surface integrity and the tool life [25,26]. Thus, adding more limitations in the aerospace production procedure [27].Despite, the extensive to optimize separate machining process of both materials, the machining process suffers when it comes to production time, cost, and assembly positional error. Single process drilling of the CFRP and Ti6Al4V materials in situ, also known as stacked drilling shows considerable benefits to overcome separate drilling issues [1][2][3]28,29]. However, the stack drilling o...

show abstract

Section: Effect Of Tool Wear On the Thrust Forcementioning

confidence: 90%

Section: Effect Of Tool Wear On the Thrust Forcementioning

confidence: 99%

mentioning

confidence: 99%

See 1 more Smart Citation

An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

Hussein

Sadek

Elbestawi

et al. 2019

JMMP

View full text Add to dashboard Cite

show abstract

“…In the case of the external application, a mixture of compressed air and oil is fed via an external nozzle to the cutting zone from a chamber. In contrast to this, there are two possible methods for the external application of oil and air or aerosol ( Figure 4 Out of the four combinations mentioned above, the dual-channel internal system was reported to be the ideal configuration, especially for drilling and boring operations [53][54][55]. For example, Zeilmann and Weingaertner analyzed the drilling temperature of Ti-6Al-4V titanium alloy under MQL conditions using different delivery methods (internal and external) [53].…”

Section: Types Of Mql Delivery Systemsmentioning

confidence: 99%

A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining

Boswell

Islam

Davies

et al. 2017

Int J Adv Manuf Technol

189

View full text Add to dashboard Cite

Government legislation and public opinion are the main drivers behind the movement of manufacturing companies towards sustainable production. Fundamentally, companies want to avoid future financial penalties and the industry is therefore under pressure to adapt new techniques and practices in order to become environmentally friendly. The cost efficiency of metal cutting operations is highly dependent on accuracy, excellent surface finish and minimised tool wear and, to this end, has traditionally made abundant use of cutting fluid in machining operations. However, these cutting fluids have been a major contributor to environmental and health issues. In recent years an enormous effort to eradicate these adverse effects has been made with one important focus being the implementation of minimum quantity lubrication (MQL). In the present work the authors have reviewed the current state of the art in MQL with a particular focus on drilling, turning, milling and grinding machining operations.Overall it is concluded that MQL has huge potential as a substitute for conventional flood cooling.

show abstract

“…Rahim worked on high speed drilling of Ti in the direction of uncoated drill and palm oil as MQL lubricant [7,8]. Pecat brought out chip extraction index to identify suitable cutting parameters and process conditions for drilling Ti6Al4V [9]. To the people's surprise, Ti/others (CFRP , graphite , bismaleimide or Composite) Stack drilling has greatly drawn researchers' attention for their increasing widely application, processing optimization , tool wear and other related topics in drilling process has been seen in literature [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Through-Hole Exit Characteristics in Drilling Of TI6AL4V and Quality Improvement of Hole Exit

Han¹,

Wan²

2019

IJMECH

View full text Add to dashboard Cite

The removal of macro-burrs formed after drilling has always been a difficult engineering problem, especially on different-machined materials with through holes. This paper aims at presenting an investigation into hole exit characteristics of Ti6Al4V drilled. Plastic deformation at the end of the cutting process or blanking results into the forming of burr, whose degree of impact is mostly affected by the processing parameters, especially the axial feed. Series experiments were conducted to analysis the effect of processing parameter on formed burr. The volume of burr has great effect on work-piece quality and product cost, the burr height formed easily decreases because great attention from scholars and engineers has been paid to, while the burr width size despised naturally plays a great influence on product quality and machining cost. The new de-burring tool are designed and applied in experiment, the decrease in burr width is obviously found, so the removal of burrs becomes much little than that gotten in traditional tool. The resulting indicates a promising future of de-burring in practical application Journals.

show abstract

Quantitative analysis of chip extraction in drilling of Ti6Al4V

Cited by 31 publications

References 10 publications

An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining

Through-Hole Exit Characteristics in Drilling Of TI6AL4V and Quality Improvement of Hole Exit

Contact Info

Product

Resources

About