Abstract
A sequential MQL drilling of aluminum parts having complicated geometry is widespread in aerospace and automobile industries. However, heat flux generated during sequential MQL drilling can transmit into the workpiece part, causing thermal distortion and compromising its dimensional accuracy. Therefore, it is necessary to predict the thermal distortion of the workpiece part during sequential MQL drilling. A heat flux density shape in MQL drilling of a thick AlSi7 tube with a 15-mm diameter helical drill is determined after yielding the best fit between measured and calculated temperatures during MQL drilling. The heat flux density shape is sequentially applied to 8 holes in a thin AlSi7 cylindrical part using a finite element method to predict their hole center deviations due to thermal distortion. Sequential MQL drilling is made to produce 8 holes in the cylindrical part. Their hole center deviations are measured and compared to the calculated ones. Reasonable agreement between measured and calculated hole center deviations are seen.
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