Feasibility of tool configuration and the effect of tool material, and tool geometry in multi-hole simultaneous drilling
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ORIGINAL ARTICLE
Feasibility of tool configuration and the effect of tool material, and tool geometry in multi-hole simultaneous drilling of Al2024 Muhammad Aamir 1 & Majid Tolouei-Rad 1 & Khaled Giasin 2 & Ana Vafadar 1 Received: 14 June 2020 / Accepted: 23 September 2020 / Published online: 6 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The use of the multi-spindle head in drilling technology can reduce the drilling cycle time by simultaneously producing multiple holes in one go. However, selecting the appropriate drill material and geometry is critical to overcoming the challenges of multihole drilling to ensure high-quality holes. This study investigates the use of the multi-spindle head with different tool configuration, tool materials and tool geometry during multi-hole simultaneous drilling of Al2024. A comparison is made among the high-speed steel drills (diameter: 6 mm; point angle: 118°) and two different carbide drills (diameter: 6 mm and 10 mm; point angle: 140°) as well as the maximum and minimum possible centre to centre tool distances of the multi-spindle head. The experiments are based on measuring the thrust force, evaluating the hole quality in terms of surface roughness and burrs, the formation of chips and post-drilling tool conditions. The results showed that carbide drills with high point angle and smaller diameter generated less thrust force, produced higher quality holes, and formed less built-up edge due to short chips. Besides, tools of the multi-spindle head can be adjusted in any position without affecting the hole quality which is useful for increasing productivity at a higher rate in manufacturing industries. Keywords Multi-spindle head . Tool configuration . Tool material . Tool geometry . Hole quality
Nomenclature B BUE CTCD D (mm) F (N) f (mm/rev) HSS
Burrs Built-up edge Centre to centre tool distance Diameter Cutting force Feed High-speed steel
n (rpm) Ra (μm) Vc (m/min) Vf (mm/min) Y Z (mm) θ (°) Ψ (°)
Spindle speed Surface roughness Cutting speed Feed speed Circularity error Hole size Point angle Clearance angle
* Muhammad Aamir [email protected]
1 Introduction
* Khaled Giasin [email protected]
Drilling is the most important machining operation for producing holes in the production of a part [1]. The drilling process is used in many applications such as the aerospace, aircraft, and automotive industries [2]. In automotive industries, 40% of the total material removal process is carried out using the drilling process [3]. Furthermore, it is estimated that in a medium-sized plane, 85,000 rivets are required for joining various parts of the aircraft to shape its final structure [4]. In addition, around 2000 holes are needed in the flap skins of the aircraft to attach them to the frame [3]. The problem in the drilling process arises due to high cutting forces, high surface roughness (Ra), the formation
Majid Tolouei-Rad [email protected] Ana Vafadar [email protected] 1
School of Engineering, Edith Cowan University, Joon
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