Evaluation of tool performance and hole quality when drilling C355 aluminium alloy using diamond coated and PCD drills

Rattachanai Rattanakit; Sein Soo; David Aspinwall; Brenden Haffner; Zhu Zhang; Dick Arnold; Peter Harden

Evaluation of tool performance and hole quality when drilling C355 aluminium alloy using diamond coated and PCD drills

Rattachanai Rattanakit, Sein Soo, David Aspinwall, Brenden Haffner, Zhu Zhang, Dick Arnold, Peter Harden

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

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Abstract

The paper details experimental work to investigate the influence of tool material/coating (uncoated carbide, chemical vapour deposited (CVD) diamond coated carbide and polycrystalline diamond (PCD)) and cutting speed (130 and 260m/min) on drill wear, cutting forces/torque and hole quality/integrity, when drilling 4.8mm diameter blind holes in cast, heat treated C355 aluminium alloy (~ 4.7% Si content). Tool flank wear after ~1680 holes was up to ~6 times higher with uncoated carbide (WC) drills compared to PCD, while thrust forces correspondingly showed a two-fold increase with the former at a cutting speed of 260m/min. Hole surface roughness produced using PCD drills did not exceed ~0.3µm Ra for all conditions tested, while it varied between 0.6 – 1.8µm Ra along the length of the hole when employing uncoated and coated WC tools, due to scoring and smearing of the workpiece. Hole roundness was below 7µm in all trials assessed. Hole cross sectional micrographs showed no significant damage or deformation of the material microstructure, with the exception of some minor pitting on surfaces produced using the uncoated WC drills.

Original language	English
Title of host publication	Proceedings of the 37th International MATADOR Conference
Editors	Srichand Hinduja, Lin Li
Publisher	Springer
Pages	173-176
Number of pages	4
ISBN (Print)	978-1-4471-4479-3
Publication status	Published - 25 Jul 2012
Event	Manufacturing Automation and Systems Technology, Applications, Design, Organisation and Management, and Research Conference, 37th - Manchester, United Kingdom Duration: 25 Jul 2012 → 27 Jul 2012

Conference

Conference	Manufacturing Automation and Systems Technology, Applications, Design, Organisation and Management, and Research Conference, 37th
Abbreviated title	37th MATADOR Conference
Country/Territory	United Kingdom
City	Manchester
Period	25/07/12 → 27/07/12

Keywords

Drilling
CVD diamond
PCD
aluminium alloy

Cite this

@inproceedings{35d61db4a2aa48f9a3751936f79552fa,

title = "Evaluation of tool performance and hole quality when drilling C355 aluminium alloy using diamond coated and PCD drills",

abstract = "The paper details experimental work to investigate the influence of tool material/coating (uncoated carbide, chemical vapour deposited (CVD) diamond coated carbide and polycrystalline diamond (PCD)) and cutting speed (130 and 260m/min) on drill wear, cutting forces/torque and hole quality/integrity, when drilling 4.8mm diameter blind holes in cast, heat treated C355 aluminium alloy (~ 4.7% Si content). Tool flank wear after ~1680 holes was up to ~6 times higher with uncoated carbide (WC) drills compared to PCD, while thrust forces correspondingly showed a two-fold increase with the former at a cutting speed of 260m/min. Hole surface roughness produced using PCD drills did not exceed ~0.3µm Ra for all conditions tested, while it varied between 0.6 – 1.8µm Ra along the length of the hole when employing uncoated and coated WC tools, due to scoring and smearing of the workpiece. Hole roundness was below 7µm in all trials assessed. Hole cross sectional micrographs showed no significant damage or deformation of the material microstructure, with the exception of some minor pitting on surfaces produced using the uncoated WC drills.",

keywords = "Drilling, CVD diamond, PCD, aluminium alloy",

author = "Rattachanai Rattanakit and Sein Soo and David Aspinwall and Brenden Haffner and Zhu Zhang and Dick Arnold and Peter Harden",

year = "2012",

month = jul,

day = "25",

language = "English",

isbn = "978-1-4471-4479-3",

pages = "173--176",

editor = "Srichand Hinduja and Lin Li",

booktitle = "Proceedings of the 37th International MATADOR Conference",

publisher = "Springer",

note = " Manufacturing Automation and Systems Technology, Applications, Design, Organisation and Management, and Research Conference, 37th, 37th MATADOR Conference ; Conference date: 25-07-2012 Through 27-07-2012",

}

Rattanakit, R, Soo, S, Aspinwall, D, Haffner, B, Zhang, Z, Arnold, D & Harden, P 2012, Evaluation of tool performance and hole quality when drilling C355 aluminium alloy using diamond coated and PCD drills. in S Hinduja & L Li (eds), Proceedings of the 37th International MATADOR Conference., 5-13, Springer, pp. 173-176, Manufacturing Automation and Systems Technology, Applications, Design, Organisation and Management, and Research Conference, 37th, Manchester, United Kingdom, 25/07/12.

Evaluation of tool performance and hole quality when drilling C355 aluminium alloy using diamond coated and PCD drills. / Rattanakit, Rattachanai; Soo, Sein; Aspinwall, David et al.
Proceedings of the 37th International MATADOR Conference. ed. / Srichand Hinduja; Lin Li. Springer, 2012. p. 173-176 5-13.

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

TY - GEN

T1 - Evaluation of tool performance and hole quality when drilling C355 aluminium alloy using diamond coated and PCD drills

AU - Rattanakit, Rattachanai

AU - Soo, Sein

AU - Aspinwall, David

AU - Haffner, Brenden

AU - Zhang, Zhu

AU - Arnold, Dick

AU - Harden, Peter

PY - 2012/7/25

Y1 - 2012/7/25

N2 - The paper details experimental work to investigate the influence of tool material/coating (uncoated carbide, chemical vapour deposited (CVD) diamond coated carbide and polycrystalline diamond (PCD)) and cutting speed (130 and 260m/min) on drill wear, cutting forces/torque and hole quality/integrity, when drilling 4.8mm diameter blind holes in cast, heat treated C355 aluminium alloy (~ 4.7% Si content). Tool flank wear after ~1680 holes was up to ~6 times higher with uncoated carbide (WC) drills compared to PCD, while thrust forces correspondingly showed a two-fold increase with the former at a cutting speed of 260m/min. Hole surface roughness produced using PCD drills did not exceed ~0.3µm Ra for all conditions tested, while it varied between 0.6 – 1.8µm Ra along the length of the hole when employing uncoated and coated WC tools, due to scoring and smearing of the workpiece. Hole roundness was below 7µm in all trials assessed. Hole cross sectional micrographs showed no significant damage or deformation of the material microstructure, with the exception of some minor pitting on surfaces produced using the uncoated WC drills.

AB - The paper details experimental work to investigate the influence of tool material/coating (uncoated carbide, chemical vapour deposited (CVD) diamond coated carbide and polycrystalline diamond (PCD)) and cutting speed (130 and 260m/min) on drill wear, cutting forces/torque and hole quality/integrity, when drilling 4.8mm diameter blind holes in cast, heat treated C355 aluminium alloy (~ 4.7% Si content). Tool flank wear after ~1680 holes was up to ~6 times higher with uncoated carbide (WC) drills compared to PCD, while thrust forces correspondingly showed a two-fold increase with the former at a cutting speed of 260m/min. Hole surface roughness produced using PCD drills did not exceed ~0.3µm Ra for all conditions tested, while it varied between 0.6 – 1.8µm Ra along the length of the hole when employing uncoated and coated WC tools, due to scoring and smearing of the workpiece. Hole roundness was below 7µm in all trials assessed. Hole cross sectional micrographs showed no significant damage or deformation of the material microstructure, with the exception of some minor pitting on surfaces produced using the uncoated WC drills.

KW - Drilling

KW - CVD diamond

KW - PCD

KW - aluminium alloy

M3 - Conference contribution

SN - 978-1-4471-4479-3

SP - 173

EP - 176

BT - Proceedings of the 37th International MATADOR Conference

A2 - Hinduja, Srichand

A2 - Li, Lin

PB - Springer

T2 - Manufacturing Automation and Systems Technology, Applications, Design, Organisation and Management, and Research Conference, 37th

Y2 - 25 July 2012 through 27 July 2012

ER -

Evaluation of tool performance and hole quality when drilling C355 aluminium alloy using diamond coated and PCD drills

Abstract

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Keywords

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