Analyzing the Potential of Drill Bits 3D Printed Using the Direct Metal Laser Melting (DMLM) Technology to Drill Holes in Polyamide 6 (PA6)
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussion
4. Conclusions
- Three-dimensional (3D) printed steel 1.2709 drill bits are suitable for drilling holes in polyamide 6 (PA6) and can be used as an alternative to HSS steel drill bits in the test range conducted;
- Material allowances are required for 3D printed drill bits because of the insufficient accuracy of the AM process. The allowances need to be taken into account at the design stage while creating a CAD model. The minimum radius allowance for a drill bit 12 mm in diameter is 0.25 mm per side to achieve high geometric and dimensional accuracy of the cutting tool;
- The length allowances, i.e., those along the tool axis, are required for center grinding (5 mm for a center hole at each end) and for facing (0.5−1 mm);
- The dimensional and geometric accuracy of the holes made in the polyamide 6 (PA6) by the specially designed 3D printed drill bit were higher than that reported for the HSS drill bit;
- The lowest hole roundness error of 0.019 mm was obtained for the 3D printed drill bit, when the conventionally made drill bit was used, the lowest hole roundness error was 0.018 mm higher;
- The lowest hole straightness error reported for the 3D printed drill bit was 0.021 mm and it was achieved at vc = 20 m/min and fn = 0.2 mm/rev. By contrast, the lowest hole straightness error obtained with the same process parameters for the HK 11020480 HSS drill bit was 0.042 mm, which was twice as high as that obtained for the 3D printed tool;
- The lowest hole cylindricity error measured for the 3D printed drill bit was 0.064 mm, for the HSS tool this parameter was 0.031 mm higher;
- For the 3D printed drill bit, the lowest and the highest mean values of the force acting at the x axis were 7.16 N and 10.96 N, respectively; for the force acting at the y axis, the values were 7.55 N and 10.22 N, respectively. The lowest mean square values of the forces at the x and y axes reported for the HSS drill bit were 11.06 N and 11.07 N, respectively, while the highest were 11.61 and 11.51 N, respectively.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Chemical Composition of Steel 1.2709 in wt.% | ||||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Workpiece Material | Aluminum, Al | Carbon, C | Cobalt, Co | Chromium, Cr | Manganese, Mn | Molybdenum, Mo | Nitrogen, N | Nickel, Ni | Oxygen, O | Phosphorus, P | Sulphur, S | Silicon, Si | Titanium, Ti | Iron, Fe |
Max | 0.1 | 0.03 | 10 | 0.25 | 0.15 | 5.2 | 0.1 | 19 | 0.1 | 0.01 | 0.01 | 0.1 | 1.2 | ≈65 |
Min | - | - | 8.5 | - | - | 4.5 | - | 17 | - | - | - | - | 0.8 |
Specimen | Cutting Speed vc, m/min | Feed per Revolution fn, mm/rev | Spindle Speed n, rev/min | Feed Rate vf, mm/min | Drill Bit Type |
---|---|---|---|---|---|
1,2,3 | 20 | 0.1 | 554 | 55.4 | Printed |
4,5,6 | 20 | 0.2 | 554 | 110.8 | Printed |
7,8,9 | 30 | 0.1 | 830 | 83 | Printed |
10,11,12 | 30 | 0.2 | 830 | 166 | Printed |
13,14,15 | 20 | 0.1 | 554 | 55.4 | HK 11020480 HSS |
16,17,18 | 20 | 0.2 | 554 | 110.8 | HK 11020480 HSS |
19,20,21 | 30 | 0.1 | 830 | 83 | HK 11020480 HSS |
22,23,24 | 30 | 0.2 | 830 | 166 | HK 11020480 HSS |
Parameter | CAD Model | 3D Printed Tool after Grinding | Difference |
---|---|---|---|
Drill bit diameter, mm | 12 | 11.5 | 0.5 |
Overall length, mm | 149.5 | 134.5 | 15 |
Flute length, mm | 79.5 | 71 | 8.5 |
Point angle, ° | 118 | 118 | 0 |
Parameter | Printed Tool before Grinding | Printed Tool after Grinding |
---|---|---|
CYLp, µm | 75.37 | 5.52 |
CYLv, µm | 96.04 | 2.13 |
CYLt, µm | 171.43 | 7.65 |
Error | 3D Printed Drill Bit | HK 11020480 HSS Drill Bit | |||||||
---|---|---|---|---|---|---|---|---|---|
vc = 20 m/min, fn = 0.1 mm/rev | vc = 20 m/min, fn = 0.2 mm/rev | vc = 30 m/min, fn = 0.1 mm/rev | vc = 30 m/min, fn = 0.2 mm/rev | vc = 20 m/min, fn = 0.1 mm/rev | vc = 20 m/min, fn = 0.2 mm/rev | vc = 30 m/min, fn = 0.1 mm/rev | vc = 30 m/min, fn = 0.2 mm/rev | ||
Roundness 1 | mm | 0.042 | 0.031 | 0.061 | 0.048 | 0.165 | 0.042 | 0.074 | 0.046 |
Roundness 2 | mm | 0.040 | 0.025 | 0.047 | 0.039 | 0.072 | 0.049 | 0.101 | 0.048 |
Roundness 3 | mm | 0.029 | 0.021 | 0.037 | 0.032 | 0.065 | 0.041 | 0.075 | 0.042 |
Roundness 4 | mm | 0.026 | 0.019 | 0.019 | 0.027 | 0.055 | 0.038 | 0.054 | 0.037 |
Roundness 5 | mm | 0.023 | 0.022 | 0.019 | 0.022 | 0.046 | 0.057 | 0.078 | 0.037 |
Cylindricity | mm | 0.086 | 0.064 | 0.110 | 0.084 | 0.169 | 0.119 | 0.161 | 0.095 |
Straightness 1 | mm | 0.025 | 0.021 | 0.046 | 0.027 | 0.076 | 0.054 | 0.084 | 0.050 |
Straightness 2 | mm | 0.025 | 0.023 | 0.044 | 0.029 | 0.074 | 0.051 | 0.086 | 0.042 |
Straightness 3 | mm | 0.029 | 0.022 | 0.043 | 0.028 | 0.071 | 0.053 | 0.079 | 0.054 |
Straightness 4 | mm | 0.024 | 0.022 | 0.038 | 0.028 | 0.085 | 0.056 | 0.069 | 0.047 |
Fx | Fy | Fz | Mz | |||
---|---|---|---|---|---|---|
N | N | N | Nm | |||
3D printed drill bit | vc = 20 m/min, fn = 0.1 mm/rev | 1 | 8.23 | 6.93 | 75.43 | 0.41 |
2 | 7.83 | 7.05 | 74.89 | 0.40 | ||
3 | 7.40 | 8.66 | 73.96 | 0.39 | ||
mean | 7.82 | 7.55 | 74.76 | 0.40 | ||
vc = 20 m/min, fn = 0.2 mm/rev | 1 | 7.40 | 8.66 | 73.96 | 0.39 | |
2 | 7.05 | 9.32 | 124.41 | 0.41 | ||
3 | 7.03 | 8.68 | 121.81 | 0.41 | ||
mean | 7.16 | 8.89 | 106.73 | 0.40 | ||
vc = 30 m/min, fn = 0.1 mm/rev | 1 | 8.91 | 10.16 | 66.93 | 0.85 | |
2 | 11.71 | 10.04 | 61.35 | 0.85 | ||
3 | 12.25 | 10.46 | 67.52 | 0.85 | ||
mean | 10.96 | 10.22 | 65.27 | 0.85 | ||
vc = 30 m/min, fn = 0.2 mm/rev | 1 | 6.17 | 6.90 | 75.74 | 1.64 | |
2 | 7.35 | 11.50 | 116.50 | 1.29 | ||
3 | 12.11 | 9.42 | 116.48 | 2.33 | ||
mean | 8.54 | 9.27 | 102.91 | 1.75 | ||
HK 11020480 HSS drill bit | vc = 20 m/min, fn = 0.1 mm/rev | 1 | 11.29 | 11.56 | 63.29 | 0.52 |
2 | 11.14 | 10.54 | 59.12 | 0.50 | ||
3 | 10.74 | 11.09 | 55.88 | 0.48 | ||
mean | 11,06 | 11,07 | 59.43 | 0.50 | ||
vc = 20 m/min, fn = 0.2 mm/rev | 1 | 10.77 | 11.60 | 76.06 | 0.49 | |
2 | 11.42 | 11.35 | 73.43 | 0.49 | ||
3 | 11.08 | 11.60 | 73.16 | 0.48 | ||
mean | 11,09 | 11.51 | 74.22 | 0.49 | ||
vc = 30 m/min, fn = 0.1 mm/rev | 1 | 11.58 | 10.71 | 57.55 | 0.88 | |
2 | 10.68 | 11.52 | 57.99 | 0.87 | ||
3 | 11.06 | 11.33 | 57.30 | 0.87 | ||
mean | 11.11 | 11.19 | 57.61 | 0.87 | ||
vc = 30 m/min, fn = 0.2 mm/rev | 1 | 11.39 | 11.98 | 72.14 | 0.88 | |
2 | 11.77 | 11.10 | 73.41 | 0.87 | ||
3 | 11.67 | 11.46 | 72.97 | 0.87 | ||
mean | 11.61 | 11.51 | 72.84 | 0.87 |
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Nowakowski, L.; Skrzyniarz, M.; Blasiak, S.; Rolek, J.; Vasileva, D.; Avramova, T. Analyzing the Potential of Drill Bits 3D Printed Using the Direct Metal Laser Melting (DMLM) Technology to Drill Holes in Polyamide 6 (PA6). Materials 2023, 16, 3035. https://doi.org/10.3390/ma16083035
Nowakowski L, Skrzyniarz M, Blasiak S, Rolek J, Vasileva D, Avramova T. Analyzing the Potential of Drill Bits 3D Printed Using the Direct Metal Laser Melting (DMLM) Technology to Drill Holes in Polyamide 6 (PA6). Materials. 2023; 16(8):3035. https://doi.org/10.3390/ma16083035
Chicago/Turabian StyleNowakowski, Lukasz, Michal Skrzyniarz, Slawomir Blasiak, Jaroslaw Rolek, Dimka Vasileva, and Tanya Avramova. 2023. "Analyzing the Potential of Drill Bits 3D Printed Using the Direct Metal Laser Melting (DMLM) Technology to Drill Holes in Polyamide 6 (PA6)" Materials 16, no. 8: 3035. https://doi.org/10.3390/ma16083035