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Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Authors :
Fernando Veiga
Alain Gil Del Val
Mari Luz Penalva
Octavio Pereira
Alfredo Suárez
Luis Norberto López de Lacalle Marcaide
Source :
Metals, Vol 11, Iss 7, p 1009 (2021)
Publication Year :
2021
Publisher :
MDPI AG, 2021.

Abstract

A low-frequency-assisted boring operation is a key cutting process in the aircraft manufacturing sector when drilling deep holes to avoid chip clogging based on chip breakage and, consequently, to reduce the temperature level in the cutting process. This paper proposes a predicted force model based on a commercial control-supported chip breaking function without external vibration devices in the boring operations. The model was fitted by conventional boring measurements and was validated by vibration boring experiments with different ranges of amplitude and frequency. The average prediction error is around 10%. The use of a commercial function makes the model more attractive for the industry because there is no need for intrusive vibration sensors. The low-frequency-assisted boring (LFAB) operations foster the chip breakage. Finally, the model is generic and can be used for different cutting materials and conditions. Roughness is improved by 33% when vibration conditions are optimal, considered as a vibration amplitude of half the feed per tooth. This paper presents, as a novelty, the analysis of low-frequency vibration parameters in boring processes and their effect on chip formation and internal hole roughness. This has a practical significance for the definition of a methodology based on the torque model for the selection of conditions on other hole-making processes, cutting parameters and/or materials.

Details

Language :
English
ISSN :
20754701
Volume :
11
Issue :
7
Database :
Directory of Open Access Journals
Journal :
Metals
Publication Type :
Academic Journal
Accession number :
edsdoj.66b6768a9af4dfba2f6912904a92539
Document Type :
article
Full Text :
https://doi.org/10.3390/met11071009