An Effectiveness in Manufacturing Quality on Surface Roughness and Built-Up Edge in Drilling Operation towards Aircraft Component

Abstract

Aircraft is still dominated by aluminum alloys despite the growth of composites and other lightweight materials due to their fatigue crack resistance, superior damage tolerance, and mature production methods. Assembly process of the aircraft's structures, must be involved for rivets and bolts, required a precise dimension compliance into the aviation guideline. Poor hole quality is one of the major challenges might cause cracks in the aircraft structure and reduce their reliability thus, manufacturing costs are directly affected by this rejection of parts at the assembly stage. The aim of this paper is to study on feed rate, towards surface roughness and Built Up Edges (BUE), and drilling of aluminium alloys used in aircraft component. An experimental approach was used to determine the most efficient feed rate for drilling operations. Observations were made on the BUE formation and roughness of the surface after each drill had completed up to 30 holes in order to meet the requirements of machined parts. From the experiment's findings, it was observed that the BUE formation and surface roughness both marginally changed as feed rates were varied. This experiment's most efficient feed rate was 0.15 m/min, and met the experiment's goal of determining the most efficient drilling feed rate. In conclusion, as feed rate increased, Ra (surface roughness) increased as well, while BUE decreased. While, Ra was set to a high feed rate, its value increased marginally. Drilling on aluminum alloy T6-6061 was accomplished at an efficient feed rate, resulting in improved product quality and reduced tool and workpiece damage.