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Materials 2016, 9(9), 774; doi:10.3390/ma9090774

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

1
Department of Production Engineering, Universidade Federal de Minas Gerais, Avenida Antônio Carlos, 6627, Pampulha, Belo Horizonte MG, CEP 31270-901, Brazil
2
Department of Mechanical Engineering, Universidade Federal de Minas Gerais, Avenida Antônio Carlos, 6627, Pampulha, Belo Horizonte MG, CEP 31270-901, Brazil
*
Author to whom correspondence should be addressed.
Academic Editor: Redouane Zitoune
Received: 14 July 2016 / Revised: 10 August 2016 / Accepted: 25 August 2016 / Published: 13 September 2016
(This article belongs to the Special Issue Machining of Composites and Multi-Stacks of Aerospace Materials)
View Full-Text   |   Download PDF [14161 KB, uploaded 13 September 2016]   |  

Abstract

Composite materials are widely employed in the naval, aerospace and transportation industries owing to the combination of being lightweight and having a high modulus of elasticity, strength and stiffness. Drilling is an operation generally used in composite materials to assemble the final product. Damages such as the burr at the drill entrance and exit, geometric deviations and delamination are typically found in composites subjected to drilling. Drills with special geometries and pilot holes are alternatives used to improve hole quality as well as to increase tool life. The present study is focused on the drilling of a sandwich composite material (two external aluminum plates bound to a polyethylene core). In order to minimize thrust force and burr height, the influence of drill geometry, the pilot hole and the cutting parameters was assessed. Thrust force and burr height values were collected and used to perform an analysis of variance. The results indicated that the tool and the cutting speed were the parameters with more weight on the thrust force and for burr height they were the tool and the interaction between tool and feed. The results indicated that drilling with a pilot hole of Ø4 mm exhibited the best performance with regard to thrust force but facilitated plastic deformation, thus leading to the elevation of burr height, while the lowest burr height was obtained using the Brad and Spur drill geometry. View Full-Text
Keywords: drilling; sandwich composite; pilot hole; thrust force; burr height; analysis of variance drilling; sandwich composite; pilot hole; thrust force; burr height; analysis of variance
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Rezende, B.A.; Silveira, M.L.; Vieira, L.M.G.; Abrão, A.M.; Faria, P.E.; Rubio, J.C.C. Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material. Materials 2016, 9, 774.

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