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Investigation of Interlayer Burr Formation in the Drilling of Stacked Aluminum Sheets

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Investigation of Interlayer Burr Formation in the Drilling of Stacked Aluminum Sheets Investigation of Interlayer Burr Formation in the Drilling of Stacked Aluminum Sheets A Thesis Presented to The Academic Faculty by Cody Hellstern In Partial Fulfillment of the Requirements for the Degree Master of Science in Mechanical Engineering George W. Woodruff School of Mechanical Engineering Georgia Institute of Technology May 2009 Investigation of Interlayer Burr Formation in the Drilling of Stacked Aluminum Sheets Approved by: Dr. Shreyes N. Melkote (ME, Georgia Tech), Committee Chair Dr. Steven Danyluk (ME, Georgia Tech) Dr. Rhett Mayor (ME, Georgia Tech) Date Approved: May 13, 2009 Dedicated to my parents and grandparents for always encouraging and assisting me throughout my nineteen years of education. iii ACKNOWLEDGEMENTS I would like to thank the following people for their support in the completion of this thesis: • My research advisor, Dr. Shreyes Melkote, for his constant support in guiding me in my work and helping me to complete this thesis. • John Morehouse for regularly providing assistance and helpful insight. • Steven Sheffield for teaching me how to use the PMRC equipment and always being available for help. • Thomas Newton for his thorough introduction of this project as well as all of the other PMRC students. • Dr. Steven Danyluk and Dr. Rhett Mayor for reviewing and providing advice on this thesis. • The Lockheed Martin Manufacturing Research and Integration department for their financial support and supplies of materials for testing. • Finally, I would like to thank all of my family and friends who have supported me along the way. iv TABLE OF CONTENTS DEDICATION .................................................................................................................iii ACKNOWLEDGEMENTS ............................................................................................ iv LIST OF TABLES ............................................................................................................ x LIST OF FIGURES ......................................................................................................... xi LIST OF SYMBOLS ...................................................................................................... xv SUMMARY ................................................................................................................... xvii INTRODUCTION ............................................................................................................ 1 1.1 Background and Motivation .......................................................................... 1 1.2 Problem Statement......................................................................................... 4 1.3 Research Goals............................................................................................... 4 1.4 Thesis Outline ................................................................................................ 5 LITERATURE REVIEW ................................................................................................ 6 2.1 Motivation...................................................................................................... 6 2.2 Introduction to Drilling.................................................................................. 6 2.2.1 Factors Affecting Drilling..................................................................... 6 2.2.2 Standard Drill Geometries .................................................................... 7 2.2.3 Drill Materials....................................................................................... 7 2.2.4 Other Drill Geometries ......................................................................... 7 2.2.5 Drilling Forces ...................................................................................... 9 2.2.6 Drill Wear ........................................................................................... 10 v 2.3 Introduction to Burrs.................................................................................... 11 2.3.1 Types of Burrs..................................................................................... 11 2.3.2 Burr Formation Mechanism................................................................ 13 2.3.3 Burr Measurements............................................................................. 14 2.3.4 Burr Problems ..................................................................................... 15 2.4 Burr Investigations....................................................................................... 16 2.4.1 Experimental Investigations – Drilling Parameters ............................ 16 2.4.2 Experimental Investigations – Drilling Geometries ........................... 17 2.4.3 Experimental Investigations – Wear and Workpiece Material........... 17 2.4.4 Empirical Burr Modeling.................................................................... 17 2.4.5 Finite Element Modeling of Burrs ...................................................... 18 2.4.6 Analytical Burr Modeling................................................................... 19 2.5 Interlayer Burrs ............................................................................................ 22 2.5.1 Interlayer Burr Formation................................................................... 22 2.5.2 Interlayer Burr Prevention .................................................................. 23 2.5.3 Multilayered Modeling Problems ....................................................... 25 2.5.4 Interlayer FEM Investigations ............................................................ 26 2.6 Summary...................................................................................................... 26 INTERLAYER DRILLING BURR EXPERIMENTS ................................................ 28 3.1 Goal and Approach ...................................................................................... 28 3.2 Parameter Selection ..................................................................................... 28 3.3 Experimental Procedure............................................................................... 32 3.4 Measurements .............................................................................................. 35 vi 3.4.1 Drilling Forces .................................................................................... 35 3.4.2 Burr Heights........................................................................................ 36 3.4.3 Burr Widths......................................................................................... 38 3.4.4 Drill Wear ........................................................................................... 40 3.5 Results.......................................................................................................... 42 3.5.1 Burr Heights........................................................................................ 42 3.5.2 Burr Widths and Change in Separation .............................................. 45 3.5.3 Drill Wear ........................................................................................... 46 3.5.4 Drilling Thrust and Torque ................................................................. 48 3.5.5 Summary............................................................................................. 49 3.6 Discussion.................................................................................................... 51 3.7 Summary...................................................................................................... 52 CLAMPING METHODS INVESTIGATION ............................................................. 54 4.1 Goal and Approach ...................................................................................... 54 4.2 Ideal Clamping Attributes............................................................................ 54 4.2.1 Clamping Functionality ...................................................................... 55 4.2.2 Clamping Practicality.......................................................................... 56 4.2.3 Current Clamp Comparisons............................................................... 57 4.3 New Clamping Ideas.................................................................................... 58 4.3.1 Long I-Beam Concept......................................................................... 59 4.3.2 Long Hand Clamp Concept ................................................................ 59 4.3.3 Magnetic Clamp Concept ................................................................... 60 4.3.4 Single-sided Clamping Concept ......................................................... 60 vii 4.3.5 Evaluation of Concepts....................................................................... 61 4.4 Analysis of Single-sided Clamping Idea...................................................... 63 4.5 Prototypes .................................................................................................... 68 4.6 Prototype Testing......................................................................................... 70 4.7 Summary...................................................................................................... 72 ANALYTICAL MODEL FOR INTERLAYER BURR FORMATION .................... 73 5.1 Goal and Approach ...................................................................................... 73 5.2 Analysis of Previous Models ....................................................................... 74
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