Accuracy estimation in drilling small holes on engineering plastics by a mathematical approach

2017 ◽  
Vol 232 (21) ◽  
pp. 3807-3813
Author(s):  
Alper Uysal ◽  
Mihrigül Altan
Keyword(s):  
Cutting Speed ◽  
Least Square ◽  
Apparent Difference ◽  
Mathematical Approach ◽  
Radial Error ◽  
Engineering Plastics ◽  
Cast Polyamide ◽  
Twist Drills ◽  
Drill Tool ◽  
Small Holes

Engineering plastics have wide applications in different fields of industry due to their light weight and easy shaping. In manufacturing multi-component products, assembly is an inevitable stage and drilling is one of the necessary processes before joining of the components of these products. In this study, two of the most common types of engineering plastics, polyacetal (POM) and cast polyamide (castamide), were drilled with twist drills of 0.5 mm and 1 mm diameters, under different cutting speeds and feeds. In determining the accuracy of the drilled small holes, a mathematical approach was used in which least square circle method was applied and radial error of the each drilled hole was obtained. Thus, the hole accuracy could be determined without measuring equipment such as coordinate measurement machine. It has been seen that POM gave better hole accuracy than cast polyamide due its thermal and tribological properties. The effects of feed and cutting speed on the radial error were also investigated. POM did not show apparent difference in radial error according to the cutting parameters while cast polyamide showed lower radial error in higher feeds with 0.5 mm of drill tool and lower radial error with 1 mm of drill tool. Additionally, the radial error could be reduced with decrease of spindle speed at higher feed.

The effect of the different cutting tools on the micro-geometrical surface of engineering plastics

2010 ◽  
Vol 1 (1) ◽  
pp. 102-106
Author(s):  
G. Farkas ◽  
Gabor Kalacska
Keyword(s):  
Cutting Tools ◽  
Cutting Speed ◽  
Polymer Surfaces ◽  
Depth Of Cut ◽  
Engineering Plastics

We would like to present in this article the results of the microgeometrical study of theengineering polymer surfaces and the applied cutting tools. We compare the effects of differenttechnological parameters (cutting speed, cutting feed, depth of cut) having on the microgeometricalcharacteristics (Ra, Rz) and we summarise the results and conclusions from the practical engineeringlife.

Cutting Force Empirical Model of High-Speed Precision Hard Cutting GCr15

2009 ◽  
Vol 69-70 ◽  
pp. 301-305
Author(s):  
Jing Shu Hu ◽  
Yuan Sheng Zhai ◽  
Fu Gang Yan ◽  
Yu Fu Li ◽  
Xian Li Liu
Keyword(s):  
Cutting Force ◽  
Empirical Model ◽  
High Speed ◽  
Orthogonal Design ◽  
Cutting Speed ◽  
Least Square Method ◽  
Cutting Parameters ◽  
Least Square ◽  
Physical Parameters ◽  
Hard Cutting

In the cutting process, cutting force is one of the important physical parameters, which affects the generation of cutting heat, tool life and surface precision of workpiece directly. In this paper an orthogonal design of experiment and subsequent data is analyzed using high speed finish hard cutting GCr15 whose hardness is 65HRC. Cutting speed is 200-400m/min, to study the influence of cutting parameters on cutting force, cutting force empirical model has obtained from least square method.

EVALUATION OF SURFACE ROUGHNESS PRODUCED BY NANOCUTTING COPPER STRUCTURE USING A LEAST SQUARE MEAN METHOD

2019 ◽  
Vol 27 (01) ◽  
pp. 1950081 ◽  
Author(s):  
CHUNHUI JI ◽  
SHUANGQIU SUN ◽  
BIN LIN ◽  
TIANYI SUI
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Least Square ◽  
Depth Of Cut ◽  
Real Surface ◽  
Roughness Parameters ◽  
Machined Surface ◽  
Surface Roughness Parameters ◽  
3D Surface ◽  
3D Surface Roughness

This work performed molecular dynamic simulations to study the 2D profile and 3D surface topography in the nanometric cutting process. The least square mean method was used to model the evaluation criteria for the surface roughness at the nanometric scale. The result showed that the cutting speed was the most important factor influencing the spacing between the peaks, the sharpness of the peaks, and the randomness of the profile. The plastic deformation degree of the machined surface at the nanometric scale was significantly influenced by the cutting speed and depth of cut. The 2D and 3D surface roughness parameters exhibited a similar variation tendency, and the parameters Ra and Rq tended to increase gradually with an increase in the cutting speed and a decrease in the depth of cut. Finally, it is concluded that at the nanometric scale, the 3D surface roughness parameters could more accurately reflect the real surface characteristics than the 2D parameters.

Delamination-Free Drilling of Composite Laminates

1994 ◽  
Vol 116 (4) ◽  
pp. 475-481 ◽  
Author(s):  
S. Jain ◽  
D. C. H. Yang
Keyword(s):  
Composite Laminates ◽  
Thrust Force ◽  
Tool Geometry ◽  
Elliptical Plate ◽  
Hole Quality ◽  
Drilling Operation ◽  
Twist Drills ◽  
Drill Tool

Composite laminates in significant numbers are rendered unacceptable due to delamination that occurs during the drilling operation. Thrust generated during the drilling operation is identified as responsible for delamination. Expressions developed for critical thrusts and critical feed rates, by modeling the delamination zone as an elliptical plate in unidirectional laminates, appear to be fairly accurate. It has been demonstrated that the critical thrusts and feed rates obtained for unidirectional laminates can be conservatively used for multi-directional laminates. With regard to the tool geometry, the chisel edge width appears to be the single most important factor contributing to the thrust force and hence delamination. A diamond-impregnated tubular drill tool was designed and tested. This tool resulted in a much smaller thrust and much better hole quality as compared with the standard twist drills.

EXPERIMENTAL STUDIES ON THRUST FORCE AND TORQUE DURING DRILLING OF GLASS FIBER REINFORCED PLASTIC WITH SIC FILLERS

2010 ◽  
Vol 09 (01) ◽  
pp. 63-72 ◽  
Author(s):  
M. SENTHIL KUMAR
Keyword(s):  
Thrust Force ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Gfrp Composites ◽  
Glass Fiber Reinforced Plastic ◽  
Fiber Reinforced Plastic ◽  
Glass Fiber Reinforced ◽  
Reinforced Plastic ◽  
Influencing Parameters ◽  
Twist Drills

The paper discusses the study on thrust force and torque while drilling GFRP composites with SiC fillers. The input parameters such as cutting speed, feed rate and point angle were varied and influencing parameters such as thrust force and torque were studied. The experimental investigation was made during the drilling of GFRP with SiC fillers using four standard twist drills of point angles 90°, 100°, 110° and 120°.

Determination of Surface and Hole Quality in Drilling of AISI D2 Cold Work Tool Steel Using MPMR, MARS and LSSVM

2014 ◽  
Vol 13 (04) ◽  
pp. 237-246 ◽  
Author(s):  
Pijush Samui
Keyword(s):  
Tool Steel ◽  
Cold Work ◽  
Cutting Speed ◽  
Least Square ◽  
Support Vector ◽  
Hole Quality ◽  
Aisi D2 ◽  
Cemented Carbide Drills ◽  
Coated Cemented Carbide ◽  
Cold Work Tool Steel

This paper adopts Minimax Probability Machine Regression (MPMR), Multivariate Adaptive Regression Spline (MARS), and Least Square Support Vector Machine (LSSVM) for prediction of surface and hole quality in drilling of AISI D2 cold work tool steel with uncoated titanium nitride (TiN) and titanium aluminum nitride (TiAlN) monolayer- and TiAlN/TiN multilayer-coated-cemented carbide drills. MPMR is a probabilistic model. MARS is a nonparametric regression technique. LSSVM is developed based on statistical learning algorithm. Cutting tool (t), Feed rate (fr)(mm/rev), and Cutting speed (v)(m/min) have been adopted as inputs of MPMR, MARS, and LSSVM. The output of MPMR, MARS, and LSSVM is Surface roughness (rs) (μm) and Roundness error (re) (μm). A comparative study has been presented between the developed models. The results show that the developed model gives excellent performance.

Machining Efficiency Model Based on the Multiple Regression Theory in Turning Glass Ceramics

2012 ◽  
Vol 201-202 ◽  
pp. 1092-1095
Author(s):  
Lian Jie Ma ◽  
Ai Bing Yu ◽  
Ya Dong Gong
Keyword(s):  
Prediction Model ◽  
Multiple Regression ◽  
Removal Rate ◽  
High Reliability ◽  
Cutting Speed ◽  
Glass Ceramics ◽  
Least Square Method ◽  
Least Square ◽  
Feed Speed ◽  
Tools Wear

The materials removal rate (V/VB) was selected to be objective function. It is comprehensive parameter about materials and tools wear. Through turning glass ceramics experimentation, the materials removal influence of cutting speed, cutting depth and feed speed were study. Based on least square method, the multiple regression prediction model of materials removal rate was built. And the model was tested. It was applied to predictive and control. The results indicated: this model was well to express materials removal law in turning glass ceramics. The multiple regression prediction model is high remarkable. The prediction value was coincident with measure value. This model is high reliability. So, expect materials removal rate can been obtained by this model, and choosing the technological parameter can been guided.

Study on Drilling of Al/Al2O3/Gr Hybrid Particulate Composites

2015 ◽  
Vol 766-767 ◽  
pp. 852-857 ◽  
Author(s):  
A. Saravana Kumar ◽  
P. Sasikumar ◽  
N. Nilavusri
Keyword(s):  
Experimental Investigation ◽  
Taguchi Method ◽  
Alumina Particle ◽  
Hybrid Composites ◽  
Cutting Speed ◽  
Particulate Composites ◽  
Exit Hole ◽  
Burr Height ◽  
Solid Carbide ◽  
Twist Drills

This study presents an experimental investigation on the effects of cutting speed, feed and percentage of alumina particle on the burr height in drilling of Al 6063 reinforced with Al2O3 and Gr particles using solid carbide twist drills of 6 mm diameter. Taguchi method with three factors at three levels is employed to analyze the drilling characteristics of these composites. For all cutting conditions, Al 6063/6%Al2O3/1%Gr composite has lower burr height values than other fabricated composites. The results revealed that exit hole burr height are greatly influenced by the feed rate rather than the speed for all the samples of hybrid composites.

In-Process Monitoring and Prediction of Surface Roughness in CNC Turning Process

2011 ◽  
Vol 199-200 ◽  
pp. 1958-1966 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Accuracy ◽  
Cutting Speed ◽  
Least Square ◽  
Depth Of Cut ◽  
Turning Process ◽  
Roughness Model ◽  
Force Ratio ◽  
Cnc Turning Process

The objective of this research is to propose a practical model to predict the in-process surface roughness during the turning process by using the cutting force ratio. The proposed in-process surface roughness model is developed based on the experimentally obtain result by employing the exponential function with six factors of the cutting speed, the feed rate, the rank angle the tool nose radius, the depth of cut, and the cutting force ratio. The multiple regression analysis is utilized to calculate the regression coefficients with the use of the least square method. The prediction accuracy of the in-process surface roughness model has been verified to monitor the in-process predicted surface roughness at 95% confident level. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It has been proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

Tool-Life Optimization in High-Speed Milling of Aeronautical Aluminum Alloy 7050-T7451

2009 ◽  
Vol 626-627 ◽  
pp. 117-122
Author(s):  
Y.Z. Pan ◽  
Xing Ai ◽  
Jun Zhao ◽  
X.L. Fu
Keyword(s):  
Aluminum Alloy ◽  
Tool Life ◽  
High Speed ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Least Square ◽  
High Speed Milling ◽  
Solid Carbide ◽  
Multi Linear Regression

A new approach is presented to optimize the tool life of solid carbide end mill in high-speed milling of 7050-T7451 aeronautical aluminum alloy. In view of this, the multi-linear regression model for tool life has been developed in terms of cutting speed and feed per tooth by means of central composite design of experiment and least-square techniques. Variance analyses were applied to check the adequacy of the predictive model and the significances of the independent parameters. Response contours of tool life and metal removal rates were generated by using response surface methodology (RSM). The analysis results show that it is possible to select an optimum combination of cutting speed and feed per tooth that improves metal removal rate without any sacrifice in tool life.

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