Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material
Abstract
:1. Introduction
2. Materials and Methods
2.1. Material
2.2. Cutting Tools
2.3. Experimental Set-Up
3. Results and Discussion
3.1. Thrust Force
3.2. Burr Height
4. Conclusions
- All investigated factors and second-order interactions significantly affected thrust force. The thrust force decreased with the elevation of the cutting speed (due to work material softening) and increased with the feed rate (higher shear area). The Brad and Spur drill geometry required a lower thrust force compared with the twist drills with two and three cutting edges and the presence of a pilot hole contributed to the reduction of the thrust force.
- Drill geometry and feed rate, as well as all the second- and third-order interactions, were the factors that significantly affected the burr height. The Brad and Spur geometry was responsible for shorter burrs and the presence of a pilot hole facilitated plastic deformation, thus leading to the elevation of the burr height.
Acknowledgments
Author Contributions
Conflicts of Interest
References
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Modulus of Elasticity (GPa) | Tensile Strength (MPa) | Tensile Strength (MPa) |
---|---|---|
6.51 ± 1.28 | 30.31 ± 1.78 | 4.5 ± 1.4 |
Parameters | Levels | |||||
---|---|---|---|---|---|---|
1 | 2 | 3 | 4 | 5 | 6 | |
Drill geometry | Brad & Spur | Twist drill (2 edges) | Twist drill (3 edges) | Pilot hole (2 mm) | Pilot hole (3 mm) | Pilot hole (4 mm) |
Cutting speed (m/min) | 24 | 48 | 72 | - | - | - |
Feed (mm/rev) | 0.05 | 0.10 | 0.15 | 0.25 | - | - |
Test | Tool | Cutting Speed (m/min) | Feed (mm/rev) | Thrust Force (N) | Burr Height (mm) | ||
---|---|---|---|---|---|---|---|
1 | 1 | 1 | 1 | 66.76 | 70.53 | 0.62 | 0.23 |
2 | 1 | 1 | 2 | 79.99 | 84.85 | 0.27 | 0.13 |
3 | 1 | 1 | 3 | 104.11 | 77.87 | 0.18 | 0.09 |
4 | 1 | 1 | 4 | 94.95 | 98.43 | 0.15 | 0.10 |
5 | 1 | 2 | 1 | 75.45 | 75.27 | 0.31 | 0.16 |
6 | 1 | 2 | 2 | 69.25 | 59.96 | 0.15 | 0.08 |
7 | 1 | 2 | 3 | 94.66 | 48.54 | 0.08 | 0.11 |
8 | 1 | 2 | 4 | 77.44 | 98.87 | 0.25 | 0.16 |
9 | 1 | 3 | 1 | 55.66 | 55.28 | 0.28 | 0.34 |
10 | 1 | 3 | 2 | 50.03 | 47.70 | 0.09 | 0.17 |
11 | 1 | 3 | 3 | 42.30 | 55.21 | 0.10 | 0.06 |
12 | 1 | 3 | 4 | 46.84 | 43.23 | 0.16 | 0.37 |
13 | 2 | 1 | 1 | 65.77 | 75.52 | 0.14 | 0.65 |
14 | 2 | 1 | 2 | 88.47 | 89.03 | 0.45 | 0.56 |
15 | 2 | 1 | 3 | 85.28 | 86.98 | 0.47 | 0.77 |
16 | 2 | 1 | 4 | 96.68 | 96.04 | 0.69 | 0.72 |
17 | 2 | 2 | 1 | 65.02 | 66.62 | 0.22 | 0.24 |
18 | 2 | 2 | 2 | 74.20 | 76.42 | 0.34 | 0.69 |
19 | 2 | 2 | 3 | 77.62 | 77.04 | 0.59 | 0.46 |
20 | 2 | 2 | 4 | 73.27 | 78.97 | 0.62 | 0.69 |
21 | 2 | 3 | 1 | 57.86 | 60.51 | 0.34 | 0.21 |
22 | 2 | 3 | 2 | 65.20 | 68.02 | 0.31 | 0.25 |
23 | 2 | 3 | 3 | 65.12 | 63.23 | 0.40 | 0.49 |
24 | 2 | 3 | 4 | 63.43 | 63.08 | 0.79 | 0.97 |
25 | 3 | 1 | 1 | 87.58 | 148.10 | 0.33 | 0.36 |
26 | 3 | 1 | 2 | 184.21 | 185.51 | 0.23 | 0.36 |
27 | 3 | 1 | 3 | 127.62 | 165.18 | 0.45 | 0.15 |
28 | 3 | 1 | 4 | 176.49 | 170.67 | 0.13 | 1.57 |
29 | 3 | 2 | 1 | 98.65 | 144.13 | 0.76 | 0.36 |
30 | 3 | 2 | 2 | 121.70 | 159.45 | 0.31 | 0.61 |
31 | 3 | 2 | 3 | 144.45 | 164.17 | 0.18 | 0.30 |
32 | 3 | 2 | 4 | 147.02 | 164.05 | 0.22 | 0.13 |
33 | 3 | 3 | 1 | 118.66 | 136.72 | 0.19 | 0.57 |
34 | 3 | 3 | 2 | 153.27 | 124.28 | 0.31 | 0.91 |
35 | 3 | 3 | 3 | 142.99 | 141.65 | 0.19 | 0.15 |
36 | 3 | 3 | 4 | 123.76 | 129.25 | 0.31 | 0.15 |
37 | 4 | 1 | 1 | 17.95 | 20.21 | 0.61 | 0.47 |
38 | 4 | 1 | 2 | 24.11 | 27.28 | 0.22 | 0.28 |
39 | 4 | 1 | 3 | 37.69 | 31.09 | 3.50 | 3.52 |
40 | 4 | 1 | 4 | 44.81 | 33.59 | 1.46 | 1.44 |
41 | 4 | 2 | 1 | 17.31 | 15.91 | 0.19 | 0.28 |
42 | 4 | 2 | 2 | 18.36 | 17.89 | 0.38 | 0.37 |
43 | 4 | 2 | 3 | 18.15 | 18.93 | 0.61 | 0.49 |
44 | 4 | 2 | 4 | 25.48 | 29.54 | 2.20 | 2.23 |
45 | 4 | 3 | 1 | 16.42 | 16.23 | 0.20 | 0.20 |
46 | 4 | 3 | 2 | 20.14 | 21.53 | 0.44 | 0.50 |
47 | 4 | 3 | 3 | 22.44 | 22.35 | 0.64 | 0.62 |
48 | 4 | 3 | 4 | 26.30 | 23.53 | 2.54 | 2.10 |
49 | 5 | 1 | 1 | 14.54 | 15.78 | 1.66 | 1.23 |
50 | 5 | 1 | 2 | 16.70 | 19.18 | 0.87 | 1.60 |
51 | 5 | 1 | 3 | 19.88 | 20.46 | 1.48 | 1.42 |
52 | 5 | 1 | 4 | 26.53 | 24.00 | 0.70 | 0.17 |
53 | 5 | 2 | 1 | 12.16 | 12.71 | 2.19 | 0.54 |
54 | 5 | 2 | 2 | 13.53 | 12.70 | 1.63 | 1.43 |
55 | 5 | 2 | 3 | 14.35 | 15.38 | 1.39 | 1.45 |
56 | 5 | 2 | 4 | 16.18 | 15.90 | 0.20 | 0.63 |
57 | 5 | 3 | 1 | 11.72 | 12.36 | 0.82 | 1.43 |
58 | 5 | 3 | 2 | 12.24 | 12.74 | 1.48 | 1.38 |
59 | 5 | 3 | 3 | 12.80 | 11.98 | 1.16 | 1.22 |
60 | 5 | 3 | 4 | 10.60 | 12.04 | 1.09 | 0.71 |
61 | 6 | 1 | 1 | 10.73 | 10.73 | 0.94 | 0.81 |
62 | 6 | 1 | 2 | 11.50 | 15.30 | 1.50 | 0.98 |
63 | 6 | 1 | 3 | 13.45 | 17.59 | 1.30 | 1.05 |
64 | 6 | 1 | 4 | 12.48 | 16.21 | 0.61 | 1.04 |
65 | 6 | 2 | 1 | 8.98 | 7.94 | 1.24 | 0.93 |
66 | 6 | 2 | 2 | 10.32 | 10.80 | 1.17 | 1.58 |
67 | 6 | 2 | 3 | 9.50 | 11.35 | 0.70 | 1.17 |
68 | 6 | 2 | 4 | 9.93 | 11.35 | 0.78 | 2.16 |
69 | 6 | 3 | 1 | 7.37 | 8.72 | 0.89 | 0.95 |
70 | 6 | 3 | 2 | 9.33 | 9.32 | 1.07 | 0.98 |
71 | 6 | 3 | 3 | 8.24 | 14.92 | 1.16 | 1.12 |
72 | 6 | 3 | 4 | 7.28 | 7.97 | 0.85 | 1.14 |
Parameters | Thrust Force (N) | Burr Height (mm) | ||||
---|---|---|---|---|---|---|
SS | F | p-Value | SS | F | p-Value | |
Tool | 312.684 | 618.25 | 0.000 | 21.2177 | 52.77 | 0.000 |
Cutting speed | 6617 | 32.71 | 0.000 | 0.4012 | 2.49 | 0.090 |
Feed | 2879 | 9.49 | 0.000 | 1.3427 | 5.57 | 0.002 |
Tool * Cutting speed | 3306 | 3.27 | 0.002 | 1.6056 | 2.00 | 0.046 |
Tool * Feed | 2877 | 1.90 | 0.038 | 15.4322 | 12.79 | 0.000 |
Cutting speed * Feed | 2059 | 3.39 | 0.005 | 2.7209 | 5.64 | 0.000 |
Tool * Cutting speed * Feed | 2855 | 0.94 | 0.561 | 9.9944 | 4.14 | 0.000 |
R2 adj | 95.75% | 80.35% |
Tool | f = 0.05 mm/rev | f = 0.15 mm/rev | f = 0.25 mm/rev |
---|---|---|---|
Brad & Spur | |||
Twist drill with 2 edges | |||
Twist drill with 3 edges | |||
Pilot hole 2 mm and Twist drill with 2 edges | |||
Pilot hole 3 mm and Twist drill with 2 edges | |||
Pilot hole 4 mm and Twist drill with 2 edges |
© 2016 by the authors; licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC-BY) license (http://creativecommons.org/licenses/by/4.0/).
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Rezende, B.A.; Silveira, M.L.; Vieira, L.M.G.; Abrão, A.M.; Faria, P.E.d.; 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. https://doi.org/10.3390/ma9090774
Rezende BA, Silveira ML, Vieira LMG, Abrão AM, Faria PEd, Rubio JCC. 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(9):774. https://doi.org/10.3390/ma9090774
Chicago/Turabian StyleRezende, Bruna Aparecida, Michele L. Silveira, Luciano M. G. Vieira, Alexandre M. Abrão, Paulo Eustáquio de Faria, and Juan C. Campos Rubio. 2016. "Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material" Materials 9, no. 9: 774. https://doi.org/10.3390/ma9090774