Skip to main content
SpringerLink
Log in

Assessment of cutting forces and hole quality in drilling Al2024 aluminium alloy: experimental and finite element study

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Machining experiments were conducted to evaluate the impact of cutting parameters on the hole quality and cutting forces in drilling Al2024-T3 aerospace alloy. Al2024-T3 specimen were drilled using Φ6-mm TiAlN-coated carbide twist drills under dry cutting conditions. The hole quality was inspected in terms of its surface roughness, burr and chip formations, hole size, circularity error and post-machining microhardness of the subsurface of the holes. An analysis of variance (ANOVA) was carried out to determine the percentage contribution of cutting parameters on cutting forces and the inspected hole quality parameters. A three-dimensional (3D) finite element (FE) model of drilling Al2024-T3 is developed using Abaqus/Explicit to predict thrust force and torque. The FE model was validated using experimental results and found to be in good agreement. The results of the study showed that the cutting parameters have a significant impact on cutting forces and inspected hole quality parameters. Drilling at feed rates of 100 and 300 mm/min and spindle speeds of 1000, 3000, and 6000 rpm are recommended for producing holes with smaller surface roughness, deviation from nominal hole size, circularity error and burrs.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Farid AA, Sharif S, Idris MH (2011) Chip morphology study in high speed drilling of Al–Si alloy. Int J Adv Manuf Technol 57(5–8):555–564

    Article  Google Scholar 

  2. Carter Ralph W, Steven Johnson W, Toivonen P, Makeev A, Newman JC Jr (2006) Effect of various aircraft production drilling procedures on hole quality. Int J Fatigue 28(8):943–950

    Article  Google Scholar 

  3. Shop MM (2010) Presetting process cuts scrap, rework. Modern machine shop, Modern machine shop

  4. Hashimura M, Chang Y, Dornfeld D (1999) Analysis of burr formation mechanism in orthogonal cutting. J Manuf Sci Eng 121(1):1–7

    Article  Google Scholar 

  5. Nouari M, List G, Girot F, Coupard D (2003) Experimental analysis and optimisation of tool wear in dry machining of aluminium alloys. Wear 255(7):1359–1368

    Article  Google Scholar 

  6. Fang N, Wu Q (2005) The effects of chamfered and honed tool edge geometry in machining of three aluminum alloys. Int J Mach Tools Manuf 45(10):1178–1187

    Article  Google Scholar 

  7. Shareef I, Natarajan M, Ajayi OO (2005) Dry machinability of aluminum alloys. In: World tribology congress III. American Society of Mechanical Engineers pp 831–832

  8. Dhanorker A, Özel TR (2006) An experimental and modeling study on meso/micro end milling process. In: ASME 2006 International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, pp 1071–1079

  9. Chern G-L (2006) Experimental observation and analysis of burr formation mechanisms in face milling of aluminum alloys. Int J Mach Tools Manuf 46(12–13):1517–1525

    Article  Google Scholar 

  10. Subbiah S, Melkote SN (2008) Effect of finite edge radius on ductile fracture ahead of the cutting tool edge in micro-cutting of Al2024-T3. Mater Sci Eng A 474(1–2):283–300

    Article  Google Scholar 

  11. Adnan AS, Subbiah S (2010) Experimental investigation of transverse vibration-assisted orthogonal cutting of AL-2024. Int J Mach Tools Manuf 50(3):294–302

    Article  Google Scholar 

  12. Haddag B, Atlati S, Nouari M, Barlier C, Zenasni M (2012) Analysis of the cutting parameters influence during machining aluminium alloy A2024-T351 with uncoated carbide inserts. Eng Trans 60(1):31–39

    Google Scholar 

  13. Mohamed SB, Mohamad WNF, Minhat M, Kasim MS, Ibrahim Z, Musanih MR (2015) Machining parameters optimization for trimming operation in a milling machine using two level factorial design. In: Applied mechanics and materials. Trans Tech Publications pp 105–110

  14. Çakır A, Yağmur S, Kavak N, Küçüktürk G, Şeker U (2015) The effect of minimum quantity lubrication under different parameters in the turning of AA7075 and AA2024 aluminium alloys. Int J Adv Manuf Technol 1–7

  15. Nouari M, List G, Girot F, Géhin D (2005) Effect of machining parameters and coating on wear mechanisms in dry drilling of aluminium alloys. Int J Mach Tools Manuf 45(12–13):1436–1442

    Article  Google Scholar 

  16. Kurt M, Bagci E, Kaynak Y (2009) Application of Taguchi methods in the optimization of cutting parameters for surface finish and hole diameter accuracy in dry drilling processes. Int J Adv Manuf Technol 40(5–6):458–469

    Article  Google Scholar 

  17. Kurt M, Kaynak Y, Bagci E (2008) Evaluation of drilled hole quality in Al 2024 alloy. Int J Adv Manuf Technol 37(11):1051–1060

    Article  Google Scholar 

  18. Köklü U (2012) Influence of the process parameters and the mechanical properties of aluminum alloys on the burr height and the surface roughness in dry drilling. Materiali Tehnologije 46(2):103–108

    Google Scholar 

  19. Davoudinejad A, Ashrafi SA, Hamzah RIR, Niazi A (2012) Experimental analysis of wear mechanism and tool life in dry drilling of Al2024. In: Advanced materials research. Trans Tech Publ pp 217–221

  20. Amini S, Paktinat H, Barani A, Tehran AF (2013) Vibration drilling of Al2024-T6. Mater Manuf Process 28(4):476–480

    Article  Google Scholar 

  21. Mohamed Elajrami HMaFBB (2013) Effect of drilling parameters on hole quality. Int J Min Metall Mech Eng 1 (4):254–257

  22. Barani A, Amini S, Paktinat H, Tehrani AF (2014) Built-up edge investigation in vibration drilling of Al2024-T6. Ultrasonics 54(5):1300–1310

    Article  Google Scholar 

  23. Abdelhafeez AM, Soo SL, Aspinwall DK, Dowson A, Arnold D (2015) Burr formation and hole quality when drilling titanium and aluminium alloys. Procedia CIRP 37:230–235

    Article  Google Scholar 

  24. Barani A, Amini S, Paktinat H, Fadaei Tehrani A (2014) Built-up edge investigation in vibration drilling of Al2024-T6. Ultrasonics 54(5):1300–1310

    Article  Google Scholar 

  25. Davim JP (2011) Modern machining technology: a practical guide. Elsevier

  26. Ko S-L, Lee J-K (2001) Analysis of burr formation in drilling with a new-concept drill. J Mater Process Technol 113(1–3):392–398. doi:10.1016/s0924-0136(01)00717-8

    Article  Google Scholar 

  27. Dandekar C, Orady E, Mallick PK (2007) Drilling characteristics of an E-glass fabric-reinforced polypropylene composite and an aluminum alloy: a comparative study. J Manuf Sci Eng 129(6):1080–1087

    Article  Google Scholar 

  28. Batzer S, Haan D, Rao P, Olson W, Sutherland J (1998) Chip morphology and hole surface texture in the drilling of cast aluminum alloys. J Mater Process Technol 79(1):72–78

    Article  Google Scholar 

  29. Isbilir O, Ghassemieh E (2011) Finite element analysis of drilling of titanium alloy. Procedia Eng 10:1877–1882

    Article  Google Scholar 

  30. Soo S, Aspinwall D, Dewes R (2004) 3D FE modelling of the cutting of Inconel 718. J Mater Process Technol 150(1):116–123

    Article  Google Scholar 

  31. Mabrouki T, Rigal J-F (2006) A contribution to a qualitative understanding of thermo-mechanical effects during chip formation in hard turning. J Mater Process Technol 176(1):214–221

    Article  Google Scholar 

  32. Chang C-S (2007) Prediction of the cutting temperatures of stainless steel with chamfered main cutting edge tools. J Mater Process Technol 190(1):332–341

    Article  Google Scholar 

  33. Hortig C, Svendsen B (2007) Simulation of chip formation during high-speed cutting. J Mater Process Technol 186(1):66–76

    Article  Google Scholar 

  34. Hua J, Shivpuri R (2004) Prediction of chip morphology and segmentation during the machining of titanium alloys. J Mater Process Technol 150(1):124–133

    Article  Google Scholar 

  35. Jeevannavar A, Hussain R (2014) Process modelling, simulation and experimental validation for prediction of chip morphology during high speed machining of Al 2024-T3. SAS TECH J 13(1):72–80

    Google Scholar 

  36. Asad M, Girardin F, Mabrouki T, Rigal J-F (2008) Dry cutting study of an aluminium alloy (A2024-T351): a numerical and experimental approach. Int J Mater Form 1(1):499–502

    Article  Google Scholar 

  37. Akram S, Jaffery SHI, Khan M, Mubashar A, Ali L A numerical investigation of effects of cutting velocity and feed rate on residual stresses in aluminum alloy Al-6061

  38. Shi G, Deng X, Shet C (2002) A finite element study of the effect of friction in orthogonal metal cutting. Finite Elem Anal Des 38(9):863–883

    Article  MATH  Google Scholar 

  39. Hazarika M, Dixit US (2014) Setup planning for machining. Springer International Publishing

  40. Shanmughasundaram P, Subramanian R (2014) Study of parametric optimization of burr formation in step drilling of eutectic Al–Si alloy–Gr composites. J Mater Res Technol 3(2):150–157

    Article  Google Scholar 

  41. Stephenson DA, Agapiou JS (2005) Metal cutting theory and practice, vol 68. CRC press

  42. Toenshoff HK, Denkena B (2013) Basics of cutting and abrasive processes. Springer

  43. Version A 6.13 Documentation (Abaqus), 2013. Abaqus user’s guide

  44. Lesuer DR (1999) Experimental investigations of material models for Ti-6A1-4V and 2024-T3 University of California, Lawrence Livermore National Laboratory, Livermore

  45. Johnson GR, Cook WH (1983) A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. In: Proceedings of the 7th International Symposium on Ballistics. The Hague, Netherlands: International Ballistics Committee, pp 541–547

  46. Mabrouki T, Girardin F, Asad M, Rigal J-F (2008) Numerical and experimental study of dry cutting for an aeronautic aluminium alloy (A2024-T351). Int J Mach Tools Manuf 48(11):1187–1197

    Article  Google Scholar 

  47. Straffelini G (2015) Friction and wear: methodologies for design and control. Springer International Publishing

  48. Cheng K (2008) Machining dynamics: fundamentals, applications and practices. Springer Science & Business Media

  49. Rao PN (2013) Manufacturing technology: metal cutting and machine tools. v. 2. Tata McGraw-Hill Education

  50. Qin Y (2015) Micromanufacturing engineering and technology. Elsevier Science

  51. Oberg E (2012) Machinery’s handbook 29th edition-full book. Industrial Press

  52. Jin X (2012) Mechanics and dynamics of micro-cutting process. Ph.D, The University of British Columbia-Vancouver

  53. Seshadri R, Naveen I, Srinivasan S, Viswasubrahmanyam M, VijaySekar K, Kumar MP (2013) Finite element simulation of the orthogonal machining process with Al 2024 T351 aerospace alloy. Procedia Eng 64:1454–1463

    Article  Google Scholar 

  54. Yang K, Liang Y-C, Zheng K-N, Bai Q-S, Chen W-Q (2011) Tool edge radius effect on cutting temperature in micro-end-milling process. Int J Adv Manuf Technol 52(9–12):905–912

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. The University of Sheffield, Sheffield, UK

    Khaled Giasin, Alma Hodzic, Vaibhav Phadnis & Sabino Ayvar-Soberanis

Authors
  1. Khaled Giasin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Alma Hodzic
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Vaibhav Phadnis
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Sabino Ayvar-Soberanis
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Khaled Giasin.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Giasin, K., Hodzic, A., Phadnis, V. et al. Assessment of cutting forces and hole quality in drilling Al2024 aluminium alloy: experimental and finite element study. Int J Adv Manuf Technol 87, 2041–2061 (2016). https://doi.org/10.1007/s00170-016-8563-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-8563-y

Keywords

Search

Navigation