Engineering Commons^™

Experimental Assessment Of Hole Quality And Tool Condition In The Machining Of An Aerospace Alloy, Muhammad Aamir, Aamer Sharif, Muhammad Z. Zahir, Khaled Giasin, Majid Tolouei-Rad

Research outputs 2022 to 2026

This paper deals with an experimental investigation of hole quality in Al2024-T3, which is one of the aerospace alloys used in aircraft fuselage skin due to its high level of resistance to fatigue crack propagation. The experiments are conducted with 6 mm uncoated carbide and HSS drill bits using a CNC machine under dry conditions and different drilling parameters. The characteristics of the hole quality are investigated in terms of its perpendicularity, cylindricity, circularity and hole size. An ANOVA (analysis of variance) and Pareto charts are used to analyze the effects of the drilling parameters on the hole quality. The …

Effect Of Cutting Parameters And Tool Geometry On The Performance Analysis Of One-Shot Drilling Process Of Aa2024-T3, Muhammad Aamir, Khaled Giasin, Majid Tolouei-Rad, Israr Ud Din, Muhammad I. Hanif, Ugur Kuklu, Danil Y. Pimenov, Muhammad Ikhlaq

Research outputs 2014 to 2021

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the …

Simultaneous Machining Of Aerospace Structural Materials Using Poly-Drills, Muhammad Aamir

Theses: Doctorates and Masters

Despite the growth of composites and other lightweight materials, aluminium alloys remain an attractive choice for the aerospace industry due to their distinct manufacturing processes, good resistance to fatigue crack growth and superior damage tolerance. In the aerospace industry, the drilling process is widely used among all the machining processes as millions of holes are required to produce riveted and bolted joints in the assembly operation of the aircraft's structures. The major challenges which arise from the drilling of these alloys are characterized by the low hole quality, which might initiate cracks within the airframe structure and reducing their reliability. …

Characterization And Performance Of Minimum Quantity Lubricants In Through-Tool Drilling, Amla Patil, Jay Raval, Tim Bangma, Immanuel Edinbarough, Bruce Tai, David Stephenson, Suleiman Obeidat, Wayne Nguyen Hung

Manufacturing & Industrial Engineering Faculty Publications and Presentations

This study characterized airborne microdroplet diameters and size distribution from two commercially available lubricants A and B for internal minimum quantity lubrication (MQL). The effects of air pressure, oil channel size, physical properties of lubricants on the resultant microdroplets and through-tool MQL drilling performance were studied. Airborne microdroplet diameters were highly sensitive to the coolant channel sizes and air pressure. Cluster method was used to divide microdroplets into smaller clusters for comparison. Experimental data show that the average airborne microdroplet of lubricant B was larger than that of lubricant A at different air pressures and channel sizes. The contact angle …

Multi-Hole Simultaneous Drilling Of Aluminium Alloy: A Preliminary Study And Evaluation Against One-Shot Drilling Process, Muhammad Aamir, Shanshan Tu, Khaled Giasin, Majid Tolouei-Rad

Research outputs 2014 to 2021

Poly-drill heads are used in mass production to increase productivity when a large number of holes are required. In this work, drilling experiments on Al5083 aluminium alloy were carried out using a poly-drill head to measure the thrust force and assess hole quality. Analysis of chip formations and post-machining tool condition were evaluated using optical microscopy. Additional drilling tests were conducted using one-shot drilling and results obtained from the two drilling techniques were evaluated against each other. The results showed that the average thrust forces obtained from poly-drill head were slightly lower than those from one-shot drilling. Improvement in hole …

Machinability Of Al2024, Al6061, And Al5083 Alloys Using Multi-Hole Simultaneous Drilling Approach, Muhammad Aamir, Majid Tolouei-Rad, Khaled Giasin, Ana Vafadar

Research outputs 2014 to 2021

Aluminium alloys are extensively used in different industries due to their good mechanical properties, machinability, low cost and reliable inspection. Drilling is one of the most important machining processes for assembly operations. The number of holes required in an assembly may vary from several holes to millions depending on the application which increases the manufacturing time and costs. In this study, a multi-spindle drill head also known as the poly-drill head is used to perform multi-hole simultaneous drilling with the aim to increase productivity. Dry drilling tests are performed on Al2024, Al6061, and Al5083 aluminium alloys using uncoated carbide …

Optimization And Modeling Of Process Parameters In Multi-Hole Simultaneous Drilling Using Taguchi Method And Fuzzy Logic Approach, Muhammad Aamir, Shanshan Tu, Majid Tolouei-Rad, Khaled Giasin, Ana Vafadar

Research outputs 2014 to 2021

In industries such as aerospace and automotive, drilling many holes is commonly required to assemble different structures where machined holes need to comply with tight geometric tolerances. Multi-spindle drilling using a poly-drill head is an industrial hole-making approach that allows drilling several holes simultaneously. Optimizing process parameters also improves machining processes. This work focuses on the optimization of drilling parameters and two drilling processes-namely, one-shot drilling and multi-hole drilling-using the Taguchi method. Analysis of variance and regression analysis was implemented to indicate the significance of drilling parameters and their impact on the measured responses i.e., surface roughness and hole size. …

Performance Analysis Of Multi-Spindle Drilling Of Al2024 With Tin And Ticn Coated Drills Using Experimental And Artificial Neural Networks Technique, Muhammad Aamir, Majid Tolouei-Rad, Ana Vafadar, Muhammad Nouman Amjad Raja, Khaled Giasin

Research outputs 2014 to 2021

Multi-spindle drilling simultaneously produces multiple holes to save time and increase productivity. The assessment of hole quality is important in any drilling process and is influenced by characteristics of the cutting tool, drilling parameters and machine capacity. This study investigates the drilling performance of uncoated carbide, and coated carbide (TiN and TiCN) drills when machining Al2024 aluminium alloy. Thrust force and characteristics of hole quality, such as the presence of burrs and surface roughness, were evaluated. The results show that the uncoated carbide drills performed better than the TiN and TiCN coated tools at low spindle speeds, while TiCN coated …

Analysis Of Surface Integrity In Machining Of Cfrp Under Different Cooling Conditions, Arjun Nagaraj

Theses and Dissertations--Mechanical Engineering

Carbon Fiber Reinforced Polymers (CFRP) are a class of advanced materials widely used in versatile applications including aerospace and automotive industries due to their exceptional physical and mechanical properties. Owing to the heterogenous nature of the composites, it is often a challenging task to machine them unlike metals. Drilling in particular, the most commonly used process for component assembly is critical especially in the aerospace sector which demands parts of highest quality and surface integrity.

Conventionally, all composites are machined under dry conditions. While there are drawbacks related to dry drilling, for example, poor surface roughness, there is a need …

Investigation Of Drilling Performance In Cryogenic Drilling On Cfrp Composite Laminates, Tian Xia

Theses and Dissertations--Mechanical Engineering

In recent years, there has been a substantial growth in the application of carbon fiber reinforced plastic (CFRP) composite materials in automobile and aerospace industries due to their superior properties such as lightweight, high strength, excellent corrosion resistance, and minimal fatigue concerns. The present study evaluates the drilling performance of woven carbon fiber reinforced plastics under both dry and cryogenic cooling conditions using uncoated solid carbide drill with a through-hole for coolant application.

The effects of the cooling conditions and the cutting parameters on drilling performance in drilling CFRP were evaluated in terms of generated thrust force, torque, cutting edge …