This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Orbital Drilling Optimization in High Speed Machining and Fatigue Life Enhancement by Orbital Roller Burnishing: Application to an Aluminum Alloy
ISSN: 0148-7191, e-ISSN: 2688-3627
Published September 16, 2019 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
Event: AeroTech Europe
Orbital drilling has proved to be advantageous to achieve aeronautical-level quality drilling (surface roughness, geometry control…) fully adapted for complex assemblies in a single operation. However, compared to conventional drilling method, this process leads to a drastic change in structure’s fatigue life probably due to a non-optimised level of residual stress. The control of the mechanical behaviour of parts obtained by orbital drilling is the goal of the European-CleanSky collaborative R&D project RODEO (Robotized Orbital Drilling Equipment and Optimized Residual Stresses, GA no.738219). In this work, an orbital drilling unit (ORBIBOT) allowing high speed machining conditions was developed by PRECISE France, that can be integrated on a lightweight industrial robot. Cutting parameters were determined through an original Tool-Material Couple optimization strategy dedicated to orbital drilling, developed with MITIS Engineering and carried out on 2024-T351 Aluminum alloy. In order to enhance the mechanical behaviour of the system (fatigue, surface hardening…), an innovative mechanical surface treatment has been introduced for investigations: orbital roller burnishing, performed right after orbital drilling. The burnisher follows a helical path around the hole axis. Orbital burnishing and its associated tool have been patented by PRECISE (N°FR16 60693). A comparative study between axial drilling, orbital drilling and orbital drilling+burnishing was done in terms of hole diameter, surface roughness, burr height, fatigue life…. Performances and quality levels obtained by using orbital drilling (with or without burnishing) are significantly different compared to conventional drilling. On open-hole samples, a significative fatigue life improvement was exhibited using orbital drilling, even more important with burnishing. Tests were performed also on filled-hole configurations. The innovative coupling of orbital drilling and burnishing tools suggested by PRECISE offers new high-speed machining opportunities, especially in the controlled strain hardening and residual stresses domains.
CitationKamgaing Souop, L., Landon, Y., Senatore, J., Daidie, A. et al., "Orbital Drilling Optimization in High Speed Machining and Fatigue Life Enhancement by Orbital Roller Burnishing: Application to an Aluminum Alloy," SAE Technical Paper 2019-01-1861, 2019, https://doi.org/10.4271/2019-01-1861.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
- Whinnem, E., Lipczynski, G., and Eriksson, I. , “Development of Orbital Drilling for the Boeing 787,” SAE Int. J. Aerosp. 1(1):6, doi:10.4271/2008-01-2317.
- Marguet, B., Wiegert, F., Lebahar, O., Bretagnol, B., Okcu, F., and Ingvar, E. , “Advanced Portable Orbital-Drilling Unit for Airbus Final Assembly Lines,” in Aerospace Technology Conference and Exposition, 2007. doi:10.4271/2007-01-3849.
- Iyer, R., Koshy, P., and Ng, E. , “Helical Milling: An Enabling Technology for Hard Machining Precision Holes in AISI D2 Tool Steel,” International Journal of Machine Tools and Manufacture 47(2):205-210, Feb. 2007, doi:10.1016/j.ijmachtools.2006.04.006.
- Olvera, D., de Lacalle, L.N.L., Urbikain, G., Lamikiz, A. et al. , “Hole Making Using Ball Helical Milling on Titanium Alloys,” Machining Science and Technology 16(2):173-188, Apr. 2012, doi:10.1080/10910344.2012.673958.
- He, G., Li, H., Jiang, Y., Qin, X. et al. , “Helical Milling of CFRP/Ti-6Al-4V Stacks with Varying Machining Parameters,” Trans. Tianjin Univ. 21(1):56-63, Jan. 2015, doi:10.1007/s12209-015-2360-9.
- Deitert, L. , “Orbital Drilling,” in Aerospace Technology Conference and Exposition, 2011. doi:10.4271/2011-01-2533.
- Sun, D. et al. , “Hole-Making Processes and Their Impacts on the Microstructure and Fatigue Response of Aircraft Alloys,” Int J Adv Manuf Technol 1-8, Dec. 2016, doi:10.1007/s00170-016-9850-3.
- Yen, Y.C., Sartkulvanich, P., and Altan, T. , “Finite Element Modeling of Roller Burnishing Process,” CIRP Annals 54(1):237-240, Jan. 2005, doi:10.1016/S0007-8506(07)60092-4.
- Balland, P., Tabourot, L., Degre, F., and Moreau, V. , “An Investigation of the Mechanics of Roller Burnishing through Finite Element Simulation and Experiments,” International Journal of Machine Tools and Manufacture 65:29-36, Feb. 2013, doi:10.1016/j.ijmachtools.2012.09.002.
- Wagner, L. , “Mechanical Surface Treatments on Titanium, Aluminum and Magnesium Alloys,” Materials Science and Engineering: A 263(2):210-216, May 1999, doi:10.1016/S0921-5093(98)01168-X.
- García-Granada, A.A., Gomez-Gras, G., Jerez-Mesa, R., Travieso-Rodriguez, J.A., and Reyes, G. , “Ball-Burnishing Effect on Deep Residual Stress on AISI 1038 and AA2017-T4,” Materials and Manufacturing Processes 32(11):1279-1289, Aug. 2017, doi:10.1080/10426914.2017.1317351.
- Balland, P., Tabourot, L., Degre, F., and Moreau, V. , “Mechanics of the Burnishing Process,” Precision Engineering 37(1):129-134, Jan. 2013, doi:10.1016/j.precisioneng.2012.07.008.
- Delgado, P., Cuesta, I.I., Alegre, J.M., and Díaz, A. , “State of the Art of Deep Rolling,” Precision Engineering 46:1-10, Oct. 2016, doi:10.1016/j.precisioneng.2016.05.001.
- Hassan, A.M. and Al-Bsharat, A.S. , “Improvements in Some Properties of Non-Ferrous Metals by the Application of the Ball-Burnishing Process,” Journal of Materials Processing Technology 59(3):250-256, May 1996, doi:10.1016/0924-0136(95)02149-3.
- Ni, W. , “Orbital Drilling of Aerospace Materials,” 2007. doi:10.4271/2007-01-3814.
- Lu, J. Handbook of Measurement Residual Stresses (US, Society for Experimental Mechanics, 1996), Chap 5, ISBN 0-88173-229-X.
- Pauze, N. , “Fatigue corrosion dans le sens travers court de tôles d’aluminium 2024-T351 présentant des défauts de corrosion localisée,” Ecole Nationale Supérieure des Mines Saint-Etienne, Saint-Etienne, 2008, https://tel.archives-ouvertes.fr/tel-00359611.
- Ball, D.L. and Lowry, D.R. , “Experimental Investigation on the Effects of Cold Expansion of Fastener Holes,” Fracture of Engineering Materials and Structures 21(1):17-34, 1998, doi:10.1046/j.1460-2695.1998.00430.x.
- ASTM E238-17a , “Standard Test Method for Pin-Type Bearing Test of Metallic Materials,” ASTM International, West Conshohocken, PA, 2017, www.astm.org.