An Experimental Investigation of the Influence of Point Angle and Fluctuation in Thrust Force On Chip Morphology

Drilling is a widely used machining method in engineering applications, playing a majorpart in machining operations. Chip morphology is an indicator, which shows thequality of machining. Especially, chip thickness ratio is a characteristic to show the levelof deformation and cutting effects during machining operations. In the present paper, theinfluences of parameters such as feed rate, spindle speed, point angle, and fluctuation sizeon the chip morphology investigated. The most influential parameter on the chip thicknesswas feed rate, while point angle on the chip width. The most favourable chip thicknessratio values and a lower fluctuation size in thrust force were achieved at 100o and 118o pointangles. Although the higher fluctuation in thrust force and chip thickness ratio values wereobserved at 136o and 154o point angles, the most favourable chip morphology was obtainedat these point angles. In other words, the higher point angles were found to be advantagesin drilling operations to obtain a better chip morphology and chip geometrical dimensions.

PDF

___

Thakre, A. A. and Soni, S. (2016) Modelling of bur size in? drilling of aluminium silicon carbide composites using response? surface methodology, Eng. Sci. Technol. Int. j., http://dx.doi.? org/10.1016/j.jetch.2016.02.007.
Chen, W. C. and Tsao, C. C. (1999) Cutting performance of? different coated twist drills, J. Mater. Process. Technol. 88, 203 – 207.
Lazar, M. B. and Xiraouchhakis, P. (2013) Mechanical load? distribution along the main cutting edges in drilling, J. Mater.? Process. Technol., 213, 245 – 260.
Kalidas, S. Devor, R. E. Kapoor, S. G. (2001) Experimental? investigation of the effect of drilling coatings on hole quality? under dry and wet drilling conditions. Surf. Coat. Technol., 148,? 117 – 128.
Taskesen, A. Kütükde, K. Biermann, D. (2013) Experimental? investigation and multi-objective analysis on drilling of boron? carbide reinforced metal matrix composites using grey relational? analysis, Measurement, 47, 321-330.
Celik, Y. H. (2014) Investigation the effect of cutting parameters? on the hole quality in drilling the Ti-6Al-4V. Mater. Technol., 95,? 669-295.
Caydas, U. and Celik, M. (2017) Investigation of the effects of? cutting parameters on the surface roughness, tool temperature and thrust force in drilling of AA 7075-T651 alloy, J. Polytech., 20(2),? 419–425.
Caydas, U. Hascalık, A. Buytoz, O. Meyveci, B. (2011) Performance evaluation of different twist drills in dry drilling of AIS?aIu s3t0e4nitic stainless steel, Mater. Manuf. Process., 26, 951-960.
Palanikumar, K. and Muniaraj, A. (2014) Experimental? investigation and analysis of thrust force in drilling cast hybrid? metal matrix (Al-15%SiC-4%graphite) composite, Measurement,? 53, 240–250.
Sultan, A. Z. Sharif, S. Kurniawan, D. (2015) Chip formation? when drilling AISI 316L stainless steel using carbide twist drill, Procedia Manufacturing, 2nd Int. Mater. Ind. Manuf. Eng. Con., MIMEC2015 4-6 February 2015, Bali Indonesia, 2, 224-229.
Samy, G. S. and Kumaran, S. T. (2017) Measurement and analysis of temperature, thrust force and surface roughness in drilling of AA (6351)-B4C composite, Measurement, 103, 1–9.
Thamizhmanii, S. and Hasan, S. (2012) Machinability study using chip thickness ratio on difficult to cut metals by CBN cutting tool, Key Eng. Mater., 504-506, 1317–1322.
Celik, Y. H. Yildiz, H. Ozek, C. (2006) Effect of cutting parameters on workpiece and tool properties during drilling of Ti-Al-4V, Wear Test., 46, 1526–1535.
Ema, S. (2012) Effect of twist drill point geometry on torque and thrust. Sci. Rep. Fac. Educ. Gifu Univ. (Nat. Sci.) 36, 165-174.
Ramesh, B. Elayaperumal, A. Satishkumar, S. (2014) Effect of the standard and special geometry design of a drill body on quality characteristics and multiple performance optimization in drilling of thick laminated composites, Procedia Eng., 12th Global Con. Manuf. Manage., GCMM 2014 97, 390-401.
Wang, J. Feng, P. Zheng, J. Zhang, J. (2016) Improving hole exit quality in rotary ultrasonic machining of ceramic matrix composites using a compound step-taper drill, Ceram. Int., 42, 13387-13394.
Paul, A. Kapoor, S. G. DeVor, R. E. (2005) Chisel edge and cutting lip shape optimization for improved twist drill point design, Int. J. Mach. Tools Manuf., 45, 421-431.
Sui, J. Kountanya, R. Guo, C. (2016) Development of a mechanistic force model for CNC drilling process simulation, Procedia Manuf., 44th Proceedings of the North America Manuf. Research Inst. SME, 5, 787–797.
Tsao, C. C. and Hocheng, H. (2003) The effect of chisel length and associated pilot hole on delamination when drilling composite materials, Int. J. Mach. Tools Manuf., 43, 1087-1092.
Ghosh, R. Sarkar, R. Paul, S. Pal, S. K. (2016) Biocompatibility and drilling performance of beta tricalcium phosphate: Yttrium phosphate bioceramic composite, Ceram. Int., 42, 8263-8273.
Ahmadi, K. and Savilov, A. (2015) Modeling the mechanics and dynamics of arbitrary edge drills, Int. J. Mach. Tools Manuf., 89, 208-220.
Saoudi, J. Zitoune, R. Mezlini, S. Gururaja, S. Seitier, P. (2016) Critical thrust force predictions during drilling: Analytical modeling and X-ray tomography quantification, Comp. Str., 153, 886–894.
Anand, S. R. and Patra, K. (2017) Mechanistic cutting force modelling for micro-drilling of CFRP composite laminates, CIRP J. Manuf. Sci. Technol., 16, 55–63.
Karimi, N. Z. Heidary, H. Minak, G. (2016) Critical thrust and feed prediction models in drilling of composite laminates, Comp. Str., 148, 19-26.
Jia, Z. Fu, R. Niu, B. Qian, B. Bai, Y. Wang, F. (2016) Novel drill structure for damage reduction in drilling CFRP composites. Int. J. Mach. Tools Manuf., 110, 55–65.
Akkurt, M. (1996) Talaş kaldırma yöntemleri ve takım tezgahları, 3rd, Birsen Press, İstanbul.
Rey, R. A. LeDref, J. Senatore, J. Landon, Y. (2016) Modelling of cutting forces in orbital drilling of titanium alloy Ti-6Al-4V, Int. J. Mach. Tools Manuf., 106, 75–88.