Deep hole drilling with twist drills: aspects of the CNC process and its real time monitoring and adaptive control

Deep hole drilling is one of the most complicated metal cutting processes and one of the most difficult to perform on CNC machine-tools or machining centres under conditions of limited manpower or unmanned operation. This research work investigates aspects of the deep hole drilling process with small diameter twist drills and presents a prototype system for real time process monitoring and adaptive control; two main research objectives are fulfilled in particular : First objective is the experimental investigation of the mechanics of the deep hole drilling process, using twist drills without internal coolant supply, in the range of diarneters Ø 2.4 to Ø4.5 mm and working length up to 40 diameters. The definition of the problems associated with the low strength of these tools and the study of mechanisms of catastrophic failure which manifest themselves well before and along with the classic mechanism of tool wear. The relationships between drilling thrust and torque with the depth of penetration and the various machining conditions are also investigated and the experimental evidence suggests that the process is inherently unstable at depths beyond a few diameters. Second objective is the design and implementation of a system for intelligent CNC deep hole drilling, the main task of which is to ensure integrity of the process and the safety of the tool and the workpiece. This task is achieved by means of interfacing the CNC system of the machine tool to an external computer which performs the following functions: On-line monitoring of the drilling thrust and torque, adaptive control of feed rate, spindle speed and tool penetration (Z-axis), indirect monitoring of tool wear by pattern recognition of variations of the drilling thrust with cumulative cutting time and drilled depth, operation as a data base for tools and workpieces and finally issuing of alarms and diagnostic messages.

Some aspects of drill performance

High speed twist drills are probably the most common of all metal cutting tools and also the least efficient. In this study, detailed research was undertaken into aspects of drill performance and ways in which drilling could be improved in short hole depths of up to two diameters. The work included an evaluation of twist drill geometry and grinding parameters. It was established that errors in point grinding lead to increased hole oversize and reduced drill life. A fundamental analysis was made to establish predictive equations for the drill torque and thrust using modified orthogonal cutting equations and empirical data. A good correlation was obtained between actual and predicted results. Two new techniques for extending twist drill life by the use of coolant feeding holes and also the application of titanium nitride coatings were evaluated. Both methods were found to have potential for improving drill performance. A completely new design of carbide tipped drill was designed and developed. The new design was tested and it compared favourably with two commercially available carbide tipped drills. In further work an entirely different type of drill point geometry was developed for the drill screw. A new design was produced which enabled the drilling time to be minimised for the low thrust forces that were likely to be used with hand held power tools.

Ocular changes and other factors relating to two forms of contact lenses:a comparative study

The work utilising a new material for contact lenses has fallen into three parts: Physioloeical considerations: Since the cornea is devoid of blood vessels, its oxygen is derived from the atmosphere. Early hydrophilic gel contact lenses interrupted the flow of oxygen and corneal insult resulted. Three techniques of fenestration were tried to overcome this problem. High speed drilling with 0.1 mm diameter twist drills. was found to be mechanically successful, but under clinical conditions mucous blockage of the fenestrations occurred. An investigation was made into the amount of oxygen arriving at the corneal interface; related to gel lens thickness. The results indicated an improvement in corneal oxygen as lens thickness was reduced. The mechanism is thought to be a form of mechanical pump. A series of clinical studies con:firmed the experimental work; the use of thin lenses removing the symptoms of corneal hypoxia. Design: The parameters of lens back curvature. lens thickness and lens diameter have been isolated and related to three criteria of vision (a) Visual acuity. (b) Visual stability and (c) Induced astigmatism. From the results achieved a revised and basically successful design of lens has been developed. Comparative study: The developed form of lens was compared with traditional lenses in a controlled survey. Twelve factors were assessed over a twenty week period of wear using a total of eighty four patients. The results of this study indicate that whilst the expected changes were noted with the traditional lens wearers, gel lens wearers showed no discernible change in any of the factors measured. ldth the exception of' one parameter. In addition to a description of' the completed l'iork. further investigations are ·sug~ested l'lhich. it is hoped. l'iould further improve the optical performance of gel lenses.

The influence of cutting tool geometry upon aspects of chip flow and tool wear:a theoretical, three dimensional examination of the cutting geometry and the shape of the twist drill

This work is undertaken in the attempt to understand the processes at work at the cutting edge of the twist drill. Extensive drill life testing performed by the University has reinforced a survey of previously published information. This work demonstrated that there are two specific aspects of drilling which have not previously been explained comprehensively. The first concerns the interrelating of process data between differing drilling situations, There is no method currently available which allows the cutting geometry of drilling to be defined numerically so that such comparisons, where made, are purely subjective. Section one examines this problem by taking as an example a 4.5mm drill suitable for use with aluminium. This drill is examined using a prototype solid modelling program to explore how the required numerical information may be generated. The second aspect is the analysis of drill stiffness. What aspects of drill stiffness provide the very great difference in performance between short flute length, medium flute length and long flute length drills? These differences exist between drills of identical point geometry and the practical superiority of short drills has been known to shop floor drilling operatives since drilling was first introduced. This problem has been dismissed repeatedly as over complicated but section two provides a first approximation and shows that at least for smaller drills of 4. 5mm the effects are highly significant. Once the cutting action of the twist drill is defined geometrically there is a huge body of machinability data that becomes applicable to the drilling process. Work remains to interpret the very high inclination angles of the drill cutting process in terms of cutting forces and tool wear but aspects of drill design may already be looked at in new ways with the prospect of a more analytical approach rather than the present mix of experience and trial and error. Other problems are specific to the twist drill, such as the behaviour of the chips in the flute. It is now possible to predict the initial direction of chip flow leaving the drill cutting edge. For the future the parameters of further chip behaviour may also be explored within this geometric model.

Getting your proteins in a twist: disease caused by prions

In recent years, a number of diseases caused by proteinaceous agents caused prions have been described. This article describes the nature of prions, how prions may cause disease, and the symptoms and pathology associated with prion diseases.

The influence of tool geometry on the performance of drilling tools

The main objective of the work presented in this thesis is to investigate the two sides of the flute, the face and the heel of a twist drill. The flute face was designed to yield straight diametral lips which could be extended to eliminate the chisel edge, and consequently a single cutting edge will be obtained. Since drill rigidity and space for chip conveyance have to be a compromise a theoretical expression is deduced which enables optimum chip disposal capacity to be described in terms of drill parameters. This expression is used to describe the flute heel side. Another main objective is to study the effect on drill performance of changing the conventional drill flute. Drills were manufactured according to the new flute design. Tests were run in order to compare the performance of a conventional flute drill and non conventional design put forward. The results showed that 50% reduction in thrust force and approximately 18% reduction in torque were attained for the new design. The flank wear was measured at the outer corner and found to be less for the new design drill than for the conventional one in the majority of cases. Hole quality, roundness, size and roughness were also considered as a further aspect of drill performance. Improvement in hole quality is shown to arise under certain cutting conditions. Accordingly it might be possible to use a hole which is produced in one pass of the new drill which previously would have required a drilled and reamed hole. A subsidiary objective is to design the form milling cutter that should be employed for milling the foregoing special flute from drill blank allowing for the interference effect. A mathematical analysis in conjunction with computing technique and computers is used. To control the grinding parameter, a prototype drill grinder was designed and built upon the framework of an existing cincinnati cutter grinder. The design and build of the new grinder is based on a computer aided drill point geometry analysis. In addition to the conical grinding concept, the new grinder is also used to produce spherical point utilizing a computer aided drill point geometry analysis.

In-fibre twist sensor based on a fibre Bragg grating with 81º tilted structure

We report a strong polarization dependent coupling behavior of fiber Bragg gratings with excessively tilted structures up to 81 . This unique property has been utilized to implement a novel twist sensor, showing high torsion sensitivity. The twist induced light coupling interchange between the two birefringence modes makes it possible to interrogate such a sensor using low-cost intensity demodulation technique.

In-fibre twist sensor based on TFBG structures

We report a novel in-fibre twist sensor utilising strong polarisation dependent coupling behaviour of fiber Bragg grating with 81° tilted structure. The demonstrated twist sensor has shown high torsion sensitivity and capability of direction recognition.

All-fibre twist sensor system based on 45 and 81 tilted fibre gratings

We experimentally demonstrated a highly sensitive twist sensor system based on a 45° and an 81° tilted fibre grating (TFG). The 81°-TFG has a set of dual-peaks that are due to the birefringence induced by its extremely tilted structure. When the 81°-TFG subjected to twist, the coupling to the two peaks would interchange from each other, providing a mechanism to measure and monitor the twist. We have investigated the performance of the sensor system by three interrogation methods (spectral, power-measurement and voltage-measurement). The experimental results clearly show that the 81°-TFG and the 45°-TFG could be combined forming a full fibre twist sensor system capable of not just measuring the magnitude but also recognising the direction of the applied twist.

The influence of twist drill design on rigidity and chip disposal

DUE TO COPYRIGHT RESTRICTIONS ONLY AVAILABLE FOR CONSULTATION AT ASTON UNIVERSITY LIBRARY AND INFORMATION SERVICES WITH PRIOR ARRANGEMENT

In-fiber twist sensor based on a fiber Bragg grating with 81° tilted structure

We report a strong polarization dependent coupling behavior of fiber Bragg gratings with excessively tilted structures up to 81°. This unique property has been utilized to implement a novel twist sensor, showing high torsion sensitivity. The twist induced light coupling interchange between the two birefringence modes makes it possible to interrogate such a sensor using low-cost intensity demodulation technique. © 2006 IEEE.

In-fibre twist sensor based on TFBG structures

We report a novel in-fibre twist sensor utilising strong polarisation dependent coupling behaviour of fiber Bragg grating with 81° tilted structure. The demonstrated twist sensor has shown high torsion sensitivity and capability of direction recognition.

All-fibre twist sensor system based on 45° and 8° tilted fibre gratings

We experimentally demonstrated a highly sensitive twist sensor system based on a 45° and an 81° tilted fibre grating (TFG). The 81°-TFG has a set of dual-peaks that are due to the birefringence induced by its extremely tilted structure. When the 81°-TFG subjected to twist, the coupling to the two peaks would interchange from each other, providing a mechanism to measure and monitor the twist. We have investigated the performance of the sensor system by three interrogation methods (spectral, power-measurement and voltage-measurement). The experimental results clearly show that the 81°-TFG and the 45°-TFG could be combined forming a full fibre twist sensor system capable of not just measuring the magnitude but also recognising the direction of the applied twist.

How earlobes can signify leadership potential

Evolutionary biologists have learned that people with greater “genetic fitness,” as manifested by a high degree of left-right body symmetry, are not just considered better looking but also tend to be healthier, more intelligent, and more dominant than others. They’re the classic alphas who rise to the top of rigidly hierarchical organizations such as the military. But our research shows that people with subtle asymmetries—for example, imbalances in ear or finger length—are often better “transformational” leaders, able to inspire followers to put self-interest aside for the good of the group. Furthermore, teams they lead outperform teams whose leaders have more-symmetrical bodies. These findings add a new twist to the debate about whether effective leaders are born or made. We believe it’s not asymmetry per se that positions people to be good transformational leaders. Instead, we argue, these individuals’ childhood responses to others’ perceptions shape them for success.

Flexibility of short-strand RNA in aqueous solution as revealed by molecular dynamics simulation:are A′-RNA and A-RNA distinct conformational structures?

We use molecular dynamics simulations to compare the conformational structure and dynamics of a 21-base pair RNA sequence initially constructed according to the canonical A-RNA and A'-RNA forms in the presence of counterions and explicit water. Our study aims to add a dynamical perspective to the solid-state structural information that has been derived from X-ray data for these two characteristic forms of RNA. Analysis of the three main structural descriptors commonly used to differentiate between the two forms of RNA namely major groove width, inclination and the number of base pairs in a helical twist over a 30 ns simulation period reveals a flexible structure in aqueous solution with fluctuations in the values of these structural parameters encompassing the range between the two crystal forms and more. This provides evidence to suggest that the identification of distinct A-RNA and A'-RNA structures, while relevant in the crystalline form, may not be generally relevant in the context of RNA in the aqueous phase. The apparent structural flexibility observed in our simulations is likely to bear ramifications for the interactions of RNA with biological molecules (e.g. proteins) and non-biological molecules (e.g. non-viral gene delivery vectors). © CSIRO 2009.