Effects of Canned Cycles and Cutting Parameters on Hole Quality in Cryogenic Drilling of Aluminum 6061-6T

Authors: M. N. Islam, B. Boswell, Y. R. Ginting

Abstract:

The influence of canned cycles and cutting parameters on hole quality in cryogenic drilling has been investigated experimentally and analytically. A three-level, three-parameter experiment was conducted by using the design-of-experiment methodology. The three levels of independent input parameters were the following: for canned cycles—a chip-breaking canned cycle (G73), a spot drilling canned cycle (G81), and a deep hole canned cycle (G83); for feed rates—0.2, 0.3, and 0.4 mm/rev; and for cutting speeds—60, 75, and 100 m/min. The selected work and tool materials were aluminum 6061-6T and high-speed steel (HSS), respectively. For cryogenic cooling, liquid nitrogen (LN2) was used and was applied externally. The measured output parameters were the three widely used quality characteristics of drilled holes—diameter error, circularity, and surface roughness. Pareto ANOVA was applied for analyzing the results. The findings revealed that the canned cycle has a significant effect on diameter error (contribution ratio 44.09%) and small effects on circularity and surface finish (contribution ratio 7.25% and 6.60%, respectively). The best results for the dimensional accuracy and surface roughness were achieved by G81. G73 produced the best circularity results; however, for dimensional accuracy, it was the worst level.

Keywords: Circularity, diameter error, drilling canned cycle, Pareto ANOVA, surface roughness.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1125551

References:

[1] Kaynak Y, Karaca HE, Noebe RD, Jawahir IS (2013) Tool-wear analysis in cryogenic machining of NiTi shape memory alloys: a comparison of tool-wear performance with dry and MQL machining. Wear 306(1–2):51–63.
[2] Hong, S. Y., Markus, I., & Jeong, W. C. (2001). New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti-6Al-4V. International Journal of Machine Tools and Manufacture, 41(15), 2245-2260.
[3] Khan, A. A., & Ahmed, M. I. (2008). Improving tool life using cryogenic cooling. Journal of materials processing technology, 196(1), 149-154.
[4] Dhar, N. R., Paul, S., & Chattopadhyay, A. B. (2001). The influence of cryogenic cooling on tool wear, dimensional accuracy and surface finish in turning AISI 1040 and E4340C steels. Wear, 249(10), 932-942.
[5] Xia, T. (2014). Investigation of Drilling Performance in Cryogenic Drilling on CFRP Composite Laminates. Master's Thesis, University of Kentucky.
[6] Pusavec, F., Hamdi, H., Kopac, J., & Jawahir, I. S. (2011). Surface integrity in cryogenic machining of nickel based alloy—Inconel 718. Journal of Materials Processing Technology, 211(4), 773-783.
[7] Ravi, S., & Kumar, M. P. (2011). Experimental investigations on cryogenic cooling by liquid nitrogen in the end milling of hardened steel. Cryogenics, 51(9), 509-515.
[8] Dinesh, S., Senthilkumar, V., Asokan, P., & Arulkirubakaran, D. (2015). Effect of cryogenic cooling on machinability and surface quality of bio-degradable ZK60 Mg alloy. Materials & Design, 87, 1030-1036.
[9] Kaynak, Y., Lu, T., & Jawahir, I. S. (2014). Cryogenic machining-induced surface integrity: A review and comparison with Dry, MQL, and Flood-cooled machining. Machining Science and Technology, 18(2), 149-198.
[10] Ahmad-Yazid, A., & Almanar, I. P. (2010). A review of cryogenic cooling in high speed machining (HSM) of mold and die steels. Scientific Research and Essays, 5(5), 412-427.
[11] Yildiz, Y., & Nalbant, M. (2008). A review of cryogenic cooling in machining processes. International Journal of Machine Tools and Manufacture, 48(9), 947-964.
[12] Kaynak, Y., Lu, T., & Jawahir, I. S. (2014). Cryogenic machining-induced surface integrity: A review and comparison with Dry, MQL, and Flood-cooled machining. Machining Science and Technology, 18(2), 149-198.
[13] Dix, M., Wertheim, R., Schmidt, G., & Hochmuth, C. (2014). Modeling of drilling assisted by cryogenic cooling for higher efficiency. CIRP Annals-Manufacturing Technology, 63(1), 73-76.
[14] Bhattacharyya D, Horrigan D (1998) A study of hole drilling in Kevlar composites. Compos Sci Technol 58(2):267–283
[15] Ahmed, L. S., Govindaraju, N., & Pradeep Kumar, M. (2015). Experimental Investigations on Cryogenic Cooling in the Drilling of Titanium Alloy. Materials and Manufacturing Processes, (just-accepted).
[16] Dhokia, V., Shokrani Chaharsooghi, A., & Newman, S. (2012). Cryogenic machining of carbon fibre. In 12th International Conference of the European Society for Precision Engineering & Nanotechnology. University of Bath.
[17] Kheireddine, A. H., Ammouri, A. H., Lu, T., Jawahir, I. S., & Hamade, R. F. (2013). An FEM analysis with experimental validation to study the hardness of in-process cryogenically cooled drilled holes in Mg AZ31b. Procedia CIRP, 8, 588-593.
[18] Govindaraju, N., Shakeel Ahmed, L., & Pradeep Kumar, M. (2014). Experimental investigations on cryogenic cooling in the drilling of AISI 1045 steel. Materials and Manufacturing Processes, 29(11-12), 1417-1421.
[19] Xia, T., Kaynak, Y., Arvin, C., & Jawahir, I. S. (2015). Cryogenic cooling-induced process performance and surface integrity in drilling CFRP composite material. The International Journal of Advanced Manufacturing Technology, 1-12.
[20] Chen, W. C., & Tsao, C. C. (1999). Cutting performance of different coated twist drills. Journal of Materials Processing Technology, 88(1), 203-207.
[21] Park, S. (1996). Robust design and analysis for quality engineering. Boom Koninklijke Uitgevers.
[22] MatWeb, Material Property Data, http://www.matweb.com/ (accessed on 11/01/2016)
[23] Galloway, D.F. (1957). Some experiments on the influence of variation factors on drill performance. Trans. ASME, 57, 191-231.
[24] Galloway, D. F., & Morton, I. S. (1946). Practical drilling tests. Research Department, The Institution of Production Engineers.
[25] Zhao, H. (1994). Predictive models for forces, power and hole oversize in drilling operations, PhD thesis, University of Melbourne.
[26] Drozda, T. J. (Ed.). (1983). Tool and Manufacturing Engineers Handbook: Machining (Vol. 1). Chapter 9. Society of Manufacturing Engineers.
[27] Islam, M. N. (1995, November). A CMM-based geometric accuracy study of CNC end milling operations. In Proceedings of sixth international conference on manufacturing engineering (pp. 835-841).
[28] Farmer, L. E. (1999). Dimensioning and tolerancing for function and economic manufacture. Blueprint Publications, Sydney.
[29] Bjørke Ø (1989). Computer-Aided tolerancing, ASME, New York.
[30] Islam, M. N., N. H. Rafi, and P. Charoon. (2009, July). An investigation into effect of canned cycles on drilled hole quality. In Proceedings of the world congress on engineering, vol. 1, pp. 761-766.
[31] Islam, M. N., Jawahir, I. S. and Kirby I. J. (1990, July). A CMM-based geometric accuracy study of CNC drilling operations. In Proceedings of fifth international conference on manufacturing engineering (pp. 378-384).