Thrust Force In Drilling Research Articles

INVESTIGATION OF BONE DRILLING FOR SECURE IMPLANT FIXATION IN HUMAN FEMURS: TAGUCHI OPTIMIZATION AND PREDICTIVE FORCE MODELS WITH EXPERIMENTAL VALIDATION

Drilling procedures are important to optimize and ensure the strongest fixation in bone fracture treatment and reconstruction surgery. The mechanistic force models currently available for bovine bones, human spines and human mandibles are not relevant to perform drilling through human femurs. The present study addresses this lack of information and aims to develop the predictive force models for drilling human femurs at different regions and directions. In this study, 10 freshly harvested cadaveric human femurs were included, and a surgical drill bit of 3.2[Formula: see text]mm diameter was used to make 4[Formula: see text]mm deep holes. Different spindle speeds (500, 1000 and 1500[Formula: see text]rpm), feed rates (40, 60 and 80[Formula: see text]mm/min), and apparent density between 0.98 and 1.98[Formula: see text]g/cm3were considered. The optimal parameters [Formula: see text], [Formula: see text], and [Formula: see text] respectively obtained for longitudinal, radial, and circumferential direction could minimize the thrust forces in bone drilling by up to 7.70, 10.50, and 16.20 N, respectively. Validation study demonstrated that the force model developed could predict the thrust force from computed tomography data sets of the patient, only with 5.05%, 6.74%, and 4.91% as a maximum error in longitudinal, radial, and circumferential direction. This important tool can assist to perform complicated surgical operations.

Prediction of critical thrust force for tubular composite in drilling-induced delamination by numerical and experimental analysis

Delamination is among the major concerns of the composite structures. Drilling often causes delamination damage at the exit of the hole when the drilling thrust is larger than the critical interlaminar strength of the composite laminates. The curved laminates endure even lower drilling thrust than the flat plates. The current study provides both numerical and experimental analysis to reveal the development of delamination initiation along with the drill movement downward. The last ply under the drill bends in response to the applied drilling thrust force until the threshold when the interlaminar strength cannot sustain and the crack starts to grow. Such onset of drilling-induced delamination can be clearly predicted by the current method. The calculated critical thrust force at the onset of delamination is compared with the experimental study and finds agreement. Knowing the material properties, the hole size and the tube diameter, one can predict the critical thrust force in drilling the composite tube and therefore able to select the proper drilling parameters including the feed rate and rotational speed for maximizing the production rate while avoiding the delamination damage during drilling a composite tube.

Multi response optimization of drilling performance of MWCNT filled banana-glass fibre reinforced composite

Natural fibres reinforced composites (NFRC) with their extended account of portion mankind are extremely significant in a broad variety of applications, and they battle and co-exist in the twenty-first century with man-made fibres, particularly as far as excellence, sustainability and cost-cutting measure of production are troubled. Numerous researchers have synthesized NFRCs using various natural fibres as well as matrix materials. Though, real-world applications of NFRCs involve some machining operations in order to complete the assembly of the parts. In this work, a technique based on the factorial design-based desirability analysis is used to determine the desired optimum machining parameters for minimum delamination, thrust force and surface roughness in drilling of MWCNT filled banana-glass natural fibres reinforced composites. The speed, federate, wt% MWCNT and point angle of drill are the most important parameters that characterize the machining operation and have been selected for investigation. Results indicated that point angle is playing major role on the responses followed by feed rate.

Effects of drilling area temperature on drilling of carbon fiber reinforced polymer composites due to temperature-dependent properties

The aim of this study was to investigate the influence of drilling area temperature on the material properties and quality of machined carbon fiber reinforced polymer (CFRP) composites. For this purpose, an epoxy resin matrix CFRP composite was chosen and tested under carefully designed temperature-controlled drilling experiments using a climatic chamber. The results show that the optimal range of drilling area temperatures is lower than the lower limit of the glass transition zone temperature (T0) of the CFRP composite and higher than the upper limit for brittle deformation (T b ) of the resin. The reason for this is that when the drilling area temperature is higher than T0, the interfacial shear strength (IFSS) and anti-deformation capacity of the CFRP composite are poor, which leads to surface roughness and a large amount of exit delamination damage. For drilling area temperatures lower than T b , the CFRP becomes more brittle leading to a substantial increase in drilling thrust force, thereby increasing the probability of exit delamination damage. By solely maintaining the drilling area temperature between T0 and T b , the interlaminar fracture toughness, anti-deformation capacity, and IFSS of the composite can be increased, thereby decreasing the probability of drilling damage.

Prediction of Thrust Force and Torque in Drilling of Glass Fiber Reinforced Plastic Using Mechanistic Force Model Approach

High strength to weight ratio along with non-corrosive characteristics make glass fiber reinforced plastics (GFRPs) most promising material in aerospace, navel, automobile and construction sector. However its non-homogeneous and anisotropic nature leads to unfavorable hole quality when subjected to drilling. Among all the drilling induced defects delamination has received considerable attention. Delamination of the material at drill entry occurs above critical torque where as it occurs above critical thrust force at drill exit which adversely affect product quality and results into rejection. Paper presents, a mechanistic approach to develop cutting force models to predict thrust force and torque in GFRP drilling. The mechanistic approach exploits different set of fundamentals of the process including speed, feed rate and tool geometry. Tool point angle, diameter and primary cutting edge effects are mainly considered in this model to predict thrust forces and torque for cutting speed and feed rate combinations. Drilling experiments were conducted on unidirectional glass fiber with stacking sequence of (0/90) sheet with carbide drill to study the influence of various combinations of speed and feed on thrust force and torque. Proposed model is validated for the drill point angle, drill diameter and primary cutting edge of drill bit for GFRP drilling over a wide range of machining conditions.

Study on mechanical properties of epoxy and nylon/epoxy composite

Present paper deals with the fabrication of synthetic fiber, Nylon Reinforced Composites (NRC) material by hand lay-up technique. In this type of composite, nylon act as a reinforcement material while epoxy resin act as the matrix material. Comparison has been made between the NRC and the pure epoxy polymer in terms of tensile strength and the drilling thrust force. The experimental results indicate that tensile strength obtained by NRC is higher than strength of pure epoxy polymer however little variation is found between the obtained values of thrust force.

Optimization of Process Parameters on Thrust Force and Delamination Factor in Drilling of Carbon Fiber Reinforced Composites

Optimization of Process Parameters on Thrust Force and Delamination Factor in Drilling of Carbon Fiber Reinforced Composites

Feasibility study of delamination in rotary ultrasonic-assisted drilling of glass fiber reinforced plastics

Glass fiber reinforced plastics are used in variety of industrial and constructional applications for their superb mechanical and physical properties. Delamination is one of the most important and prevalent damages in machining of glass fiber reinforced plastics. Diamond core drills have the capability of simultaneously drilling and grinding of fiber reinforced plastics, which results in hole quality improvement. Rotary ultrasonic-assisted drilling is the new machining process to drill holes on fiber reinforced plastics and has attracted increasing attention in recent years. In this paper, thrust force and delamination in rotary ultrasonic-assisted drilling of glass fiber reinforced plastics using diamond core drill have been investigated. A proper ultrasonic system for a core drill in ABAQUS was designed and fabricated. Influence of ultrasonic vibration and then tool grain size, fiber-volume fraction and machining parameters including spindle speed and feed rate on thrust force and delamination was investigated. Higher thrust force induces more delamination. As a result of the study, less delamination was achieved in ultrasonic-assisted mode by using a tool with larger grain size onto lower fiber-volume fraction composites. Additionally, experiments showed that lower spindle speed and higher feed rate induce more delamination.

Experimental characterization and finite element modeling of critical thrust force in cfrp drilling

ABSTRACTComposite laminates are used in many applications in ae-rospace/defense industries due to their high strength-to-weight ratio and corrosion resistance properties. In general, composite materials are hard-to-machine materials which exhibit low drilling efficiency and drilling-induced delamination damage at exit. Hence, it is important to understand the drilling processes for composite materials. This article presents a comprehensive study involving experimental characterization of drilling process to understand the cutting mechanism and relative effect of cutting parameters on delamination during drilling of carbon fiber reinforced plastic (CFRP). Thrust force and torque data are acquired for analyzing the cutting mechanism, initiation and propagation of delamination, and identification of critical thrust force below which no damage occurs. An FE model for prediction of critical thrust force has been developed and validated with experimental results. A [0/90] composite laminate is modeled simulating the last two plies in exit condition and a thin interface layer is inserted in between the plies to capture delamination extent. The tool geometry is modeled as “rigid body” with geometric features of twist drill used in experiments. The tool is indented on the workpiece to simulated tool feeding action into the workpiece. The FE model predicts the critical thrust force within 5% of the experimentally determined mean value.

EFFECT OF DRILLING PARAMETERS ON THRUST FORCE AND TORQUE DURING DRILLING OF ALUMINIUM 6061 ALLOY - BASED ON TAGUCHI DESIGN OF EXPERIMENTS

Hole generating process with drill bit called as drilling, which is very important because large portion of overall machining of any component in production industry needs assemble of parts to make a final shape with rivets and fasteners. It is well known that the drill point geometry has a significant effect on thrust force exerted by a drill bit while drilling. In this study, experimentally investigate the influence of drilling parameters such as pointangle, clearance angle, cutting speed, feed rate and drill diameter on the thrust force and torque in drilling. Drilling experiments have been conducted over a wide a range of machining conditions such as cutting speed varied in the range 500 rpm to 1000 rpm in 3steps, feed rate varied from 0.3 to 0.6mm /min in three steps using two flutesuncoated conventional twist drills of three different diameters (8, 10 and 12mm) with 1180 point and 450 helix angles. Drill bits tool geometry altered by tool&cutter grinder and obtained 1100, 1000 point angles also clearance angles varied by 40, 60 and 80. Holes are performed on Aluminium 6061 alloy material of rectangular cross section having dimensions 300mmx50mmx10mm as per taguchi technique. A kistler (type 9272), four components drill tool dynamometer was used to measure thrust force (Th) and torque (M) exerted by the drill bit during hole making on a work material further the signal was processed to a computer by a multichannel signal amplifier (Kistler 5070 type) was used to record the thrust force and torque. Finally, ANOVA test have been carried out to confirm thesignificance of factors considered during drilling and compare the predicted values with the experimental values on influence of factors on responses.

Evaluation of Thrust force in Drilling Woven roving Glass fibre reinforced Aluminium Sandwich laminates with TiAlN coated drill using Taguchi analysis

TiAlN is a high-performance coating which outshines in coarse and hard-to-machine materials like cast iron, aluminium alloys, tool steels, and nickel alloys. This paper presents the prediction and evaluation of thrust force and Torque in drilling of Woven roving Glass Fibre Reinforced Plastic and Aluminium sandwich laminate. The Prediction is based on Taguchi method. The experimental results specify that the feed rate and the drill diameter are the most significant factors affecting the thrust force, while the feed rate and spindle speed contribute the most to the surface roughness. In this study, the objective was to establish a correlation between the feed rate, spindle speed and drill diameter with the induced thrust force and Torque in drilling sandwich laminate.

Measurement and analysis of thrust force in drilling sisal-glass fiber reinforced polymer composites

Drilling of composite materials is difficult when compared to the conventional materials because of its in-homogeneous nature. The force developed during drilling play a major role in the surface quality of the hole and minimizing the damages around the surface. This paper focuses the effect of drilling parameters on thrust force in drilling of sisal-glass fiber reinforced polymer composite laminates. The quadratic response models are developed by using response surface methodology (RSM) to predict the influence of cutting parameters on thrust force. The adequacy of the models is checked by using the analysis of variance (ANOVA). A scanning electron microscope (SEM) analysis is carried out to analyze the quality of the drilled surface. From the results, it is found that, the feed rate is the most influencing parameter followed by spindle speed and the drill diameter is the least influencing parameter on the thrust force.

Measurement and analysis of temperature, thrust force and surface roughness in drilling of AA (6351)-B 4 C composite

In the present study, the drilling is performed on AA (6351)–B4C composite to analyze the influence of cutting parameters on temperature, thrust force and surface roughness. The TiN coated carbide drill tools with varying point angle such as 90°, 118° and 135° are used to conduct the experiments. Initially, the temperature rise during drilling and the effect of temperature on the chip formation are investigated by contact and non-contact measurement techniques. The reduced temperature is achieved at lower spindle speed and feed rate conditions. However, the improper selection of point angle leads to tool wear and produces poor surface finish. In addition, the thrust force generation and the delamination of the drill holes are assessed by varying the input process parameters. The thrust force is low while drilling with 135° point angle tool, but produced higher delamination. Finally, the surface roughness is examined and the Scanning Electron Microscopic (SEM) images are utilized to observe the drill hole surface morphology of the composite.

Experimental Evaluation of Various Parameters Influencing Thrust Force, Torque and Circularity in Drilling of Al based Composites using Response Surface Methodology

Background/Objectives: The application of composite materials has been increasing worldwide in all manufacturing industries. In drilling operation, the quality of hole is the basic requirement in various applications. So, the selection of optimized drilling parameters is very important for the better hole quality. Our objective is to formulate a mathematical model using response surface methodology. Methods: A series of experiments are conducted using ARIX-CNC vertical machining center on Square slabs of size 100mm x 100mm x 10mm, fabricated by stir casting method. Our work is focusing on formulating the model to investigate the effects of various drilling parameters such as spindle speed (1000, 2000 & 3000rpm), feed (0.05, 0.1 & 0.15 mm/rev) and drill tool diameter (5, 7.5 & 10mm) on thrust force, torque and circularity in drilling of Al / SiC metal matrix composite and Al / SiC / Gr hybrid composite using solid carbide drills. Findings: The experimental results on drilling of the metal matrix and hybrid composites are collected separately on L27 orthogonal array and analyzed using Signal – Noise (S/N) ratio, the analysis of variance (ANOVA) and regression analysis with the help of Design expert software and Mathematical models are developed with an objective to correlate the selected drilling parameters with drilling force, torque and circularity error in drilled holes. ANOVA is used to reveal the dominant factors that affect the responses mentioned above. Application/Improvements: The developed models are significant and the predicted values are very close to the actual values. This model can be effectively used for drilling of Al/SiC metal matrix and Al/SiC/Gr Hybrid composites within the range of the process parameters.

Effect of Cutting Speed on Thrust Force and Torque in Drilling of Glass Fiber Reinforced Polymer Based on Defects Tolerance

Glass Fiber Reinforced Polymer (GFRP) composites are being used to replace metallic materials in a wide range of industries. In the drilling of GFRP, the quality of hole is strongly dependent on process parameters. The aim of this work is to investigate the effect of cutting speed and drill material on thrust force and torque in drilling of GFRP. Drilling tests were carried out using HSS and tipped carbide twist drills and damage development during drilling was studied. The critical thrust for Iso-phthalic glass composite was found to be 60 N.

Effect of Cutting Parameters on Thrust Force and Surface Roughness in Drilling of Al-2219/B4C/Gr Metal Matrix Composites

In aluminium matrix composites, reinforcement of hard ceramic particle present inside the matrix which causes tool wear, high cutting forces and poor surface finish during machining. This paper focuses on effect of cutting parameters on thrust force, surface roughness and burr height during drilling of MMCs. In the present work, discuss the influence of spindle speed and feed rate on drilling the pure base alloy (Al-2219), mono composite (Al- 2219+8% B4C) and hybrid composite (Al-2219+8%B4C+3%Gr). The composites were fabricated using liquid metallurgy route. The drilling experiments were conducted by CNC machine with TiN coated HSS tool, M42 (Cobalt grade) and carbide tools at various spindle speeds and feed rates. The thrust force, surface roughness and burr height of the drilled hole were investigated in mono composite and hybrid composite containing graphite particles, the experimental results show that the feed rate has more influence on thrust force and surface roughness. Lesser thrust force and discontinuous chips were produced during machining of hybrid composites when compared with mono and base alloy during drilling process. It is due to solid lubricant property of graphite which reduces the lesser thrust force, burr height and lower surface roughness. When machining with Carbide tool at low feed and high speeds good surface finish was obtained compared to other two types of cutting tool materials.

In-vitro analysis of forces in conventional and ultrasonically assisted drilling of bone.

Drilling of bone is widely performed in orthopaedics for repair and reconstruction of bone. Current paper is focused on the efforts to minimize force generation during the drilling process. Ultrasonically Assisted Drilling (UAD) is a possible option to replace Conventional Drilling (CD) in bone surgical procedures. The purpose of this study was to investigate and analyze the effect of drilling parameters and ultrasonic parameters on the level of drilling thrust force in the presence of water irrigation. Drilling tests were performed on young bovine femoral bone using different parameters such as spindle speeds, feed rates, coolant flow rates, frequency and amplitudes of vibrations. The drilling force was significantly dropped with increase in drill rotation speed in both types of drilling. Increase in feed rate was more influential in raising the drilling force in CD compared to UAD. The force was significantly dropped when ultrasonic vibrations up to 10 kHz were imposed on the drill. The drill force was found to be unaffected by the range of amplitudes and the amount of water supplied to the drilling region in UAD. Low frequency vibrations with irrigation can be successfully used for safe and efficient drilling in bone.

Measurement and analysis of thrust force and torque in drilling of sisal fiber polymer composites filled with coconut shell powder

During the last few years, natural fiber (Sisal) have received much more attention than ever before from the research community. They have an outstanding potential as reinforcement in thermosets, the reinforcing materials are strong with low densities while the matrix is usually a ductile, or tough, material. The natural fiber Reinforced polymer composite materials used in general engineering applications, utilize the advantages offered by renewable resources for the development of polymer composite materials based on polymers, natural fibers and natural shell particles has been made through fabrication of Natural fiber and particulates reinforced polymer (NFPRP) composite material by using vinyl ester resin. Drilling of holes is an important machining operation to determine the assembly operations in complicated composite parts used in engineering applications. The present work focuses on optimization of the operating variable, tool geometry and the prediction of thrust force and torque of the NFPRP composite materials, and the values, compared with the Regression model and the Scheme of Delamination factor using machine vision system.

Optimal control of thrust force for delamination-free drilling in glass-fiber-reinforced plastic laminates

Damage due to delamination is an important issue during drilling in glass-fiber-reinforced plastic composite laminates. Feed-rate during drilling is the most critical parameter. High feed-rate during drilling results in high thrust force on the composite laminate. In this work, dynamics of drilling in glass-fiber-reinforced plastic composite laminates are captured in the form of third-order state-space model between thrust force and feed-rate. Optimal control is then used to control the thrust force generated during drilling. Research has revealed that there is a critical limit on thrust force during drilling in composite laminate below which no delamination occurs. This critical thrust force profile is used in this work as reference in the optimal controller to ensure delamination-free drilling. Present controller precisely tracks the given critical thrust force reference profile and gives optimal feed-rate profile. The glass-fiber-reinforced plastic composite laminate is then drilled at this optimal feed-rate profile to obtain delamination-free holes. Delamination around the holes is quantified in the form of a delamination factor. Experimental results show that the control strategy is efficient and effective in preventing drilling-induced delamination in glass-fiber-reinforced plastic composite laminates.

Experimental Investigation and Analysis on Thrust Force in Drilling of Wood Composite Medium Density Fiberboard Panels

Wood-based composites are finding increased applications over solid wood because of their important properties such as strength, aesthetic appearance, etc. to reuse the waste wood from other process and also because of the scarcity of solid wood. Medium density fiberboard (MDF) is a wood-based composite widely used in domestic, furniture manufacturing industries, construction, interior and exterior works. Machining process like drilling develops cutting force plays an important role in the quality of the final product. The cutting force developed can be controlled by the proper selection of input process parameters. The objective of this study is to analyze the influence of cutting conditions on the thrust force developed in drilling to predict the optimal cutting conditions of drilling parameters such as spindle speed, feed rate, and point angle. Taguchi design of experiments is used to perform the drilling tests. Response surface methodology (RSM) is used to develop the model to predict the influence of cutting parameters on thrust force and the adequacy of the developed model is checked with analysis of variance (ANOVA). It is revealed that the high spindle speed with low feed rate combination minimizes the thrust force in drilling of MDF panels.