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Orbital Drilling Optimization in High Speed Machining and Fatigue Life Enhancement by Orbital Roller Burnishing: Application to an Aluminum Alloy

Université de Nantes-Mathieu Ritou
INSA Toulouse-Alain Daidie
Published 2019-09-16 by SAE International in United States
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…
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