Deep-hole drilling process, monitoring system and sensors modifications

 In the drilling processes and especially deep-hole drilling process, the monitoring system and having control on mechanical parameters (e.g. Force, Torque,Vibration and Acoustic emission) are essential. The main focus of this thesis work is to study the characteristics of deep-hole drilling process, and optimize the monitoring system for controlling the process. The vibration is considered as a major defect area of the deep-hole drilling process which often leads to breakage of the drill, therefore by vibration analysis and optimizing the workpiecefixture, this area is studied by finite element method and the suggestions are explained. By study on a present monitoring system, and searching on the new sensor products, the modifications and recommendations are suggested for optimize the present monitoring system for excellent performance in deep-hole drilling process research and measurements.

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.

Deep hole drilling ...

Introduction.--Principles of deep hold drilling, by L.G. French and C.L. Goodrich.--Deep hold drilling in gun construction, by J.M.B. Scheele.--Construction of deep hole drills, by F.B. Kleinhans, O. Eckelt, and E.W. Norton.

(Table 2, page 607) Composition of manganese nodules in cores from Leg 16, Deep Sea Drilling Project

Buried manganese nodules or encrustations were encountered at five drill sites of Leg 16. Surface nodules were also sampled at two sites. With few exceptions, nodules within any one drill hole are fairly uniform in composition and are similar in composition to samples obtained previously from the eastern equatorial Pacific. Geochemical and paleontological evidence suggests that at least one of the buried samples was in situ when found and that at least one other was not. The remaining nodules may have fallen from the sediment surface to the positions in which they were found during the drilling process.

Contribution to dynamic characteristics of the cutting temperature in the drilling process considering one dimension heat flow

The machining of hardened steels has always been a great challenge in metal cutting, particularly for drilling operations. Generally, drilling is the machining process that is most difficult to cool due to the tool`s geometry. The aim of this work is to determine the heat flux and the coefficient of convection in drilling using the inverse heat conduction method. Temperature was assessed during the drilling of hardened AISI H13 steel using the embedded thermocouple technique. Dry machining and two cooling/lubrication systems were used, and thermocouples were fixed at distances very close to the hole`s wall. Tests were replicated for each condition, and were carried out with new and worn drills. An analytical heat conduction model was used to calculate the temperature at tool-workpiece interface and to define the heat flux and the coefficient of convection. In all tests using new and worn out drills, the lowest temperatures and decrease of heat flux were observed using the flooded system, followed by the MQL, considering the dry condition as reference. The decrease of temperature was directly proportional to the amount of lubricant applied and was significant in the MQL system when compared to dry cutting. (C) 2011 Elsevier Ltd. All rights reserved.

Drilling process of composite laminates – a tool based analysis

“Drilling of polymeric matrix composites structures”

Monitoring in precision metal drilling process using multi-sensors and neural network

This paper presents a new method to estimate hole diameters and surface roughness in precision drilling processes, using coupons taken from a sandwich plate composed of a titanium alloy plate (Ti6Al4V) glued onto an aluminum alloy plate (AA 2024T3). The proposed method uses signals acquired during the cutting process by a multisensor system installed on the machine tool. These signals are mathematically treated and then used as input for an artificial neural network. After training, the neural network system is qualified to estimate the surface roughness and hole diameter based on the signals and cutting process parameters. To evaluate the system, the estimated data were compared with experimental measurements and the errors were calculated. The results proved the efficiency of the proposed method, which yielded very low or even negligible errors of the tolerances used in most industrial drilling processes. This pioneering method opens up a new field of research, showing a promising potential for development and application as an alternative monitoring method for drilling processes. © 2012 Springer-Verlag London Limited.

Interstitial water chemistry, Deep Sea Drilling Project, Leg 96

On Leg 96 of the Deep Sea Drilling Project (DSDP), holes were drilled in Orca and Pigmy basins on the northern Gulf of Mexico continental slope and on the Mississippi Fan. The holes on the fan encountered interbedded sand, silt, and mud deposited extremely rapidly, most during late Wisconsin glacial time. Pore-water chemistry in these holes is variable, but does not follow lithologic changes in any simple way. Both Ca and SO4 are enriched in the pore water of many samples from the fan. Two sites drilled in the prominent central channel of the middle fan show rapid SO4 reduction with depth, whereas two nearby sites in overbank deposits show no sulfate reduction for 300 m. Calcium concentration decreases as SO4 is depleted and Li follows the same pattern. Strontium, which like Li, is enriched in samples enriched in Ca, does not decrease with SO4 and Ca. Potassium in the pore water decreases with depth at almost all sites. Sulfate reduction was active at the two basin sites and, as on the fan, this resulted in calcium carbonate precipitation and a lowering of pore water Ca, Mg, and Li. The Orca Basin site was drilled through a brine pool of 258? salinity. Pore-water salinity decreases smoothly with depth to 50 m and remains well above normal seawater values to the bottom of the hole at about 90 m. This suggests constant sedimentation under anoxic hypersaline conditions for at least the last 50,000 yr.

Pb isotopes in individual sand-sized (>150 µm) ice-rafted feldspars deposited at subpolar North Atlantic Ocean Deep Sea Drilling Project Site 611 during the late Pliocene (Marine Isotope Stages, MIS, G6 through 100)

The onset of abundant ice-rafted debris (IRD) deposition in the Nordic Seas and subpolar North Atlantic Ocean 2.72 millions of years ago (Ma) is thought to record the Pliocene onset of major northern hemisphere glaciation (NHG) due to a synchronous advance of North American Laurentide, Scandinavian and Greenland ice-sheets to their marine calving margins during marine isotope stage (MIS) G6. Numerous marine and terrestrial records from the Nordic Seas region indicate that extensive ice sheets on Greenland and Scandinavia increased IRD inputs to these seas from 2.72 Ma. The timing of ice-sheet expansion on North America as tracked by IRD deposition in the subpolar North Atlantic Ocean, however, is less clear because both Europe and North America are potential sources for icebergs in this region. Moreover, cosmogenic-dating of terrestrial tills on North America indicate that the Laurentide Ice Sheet did not extend to ~39°N until 2.4 ±0.14 Ma, at least 180 ka after the onset of major IRD deposition at 2.72 Ma. To address this problem,we present the first detailed analysis of the geochemical provenance of individual sand-sized IRD deposited in the subpolar North Atlantic Ocean between MIS G6 and 100 (~2.72-2.52 Ma). IRD provenance is assessed using laser ablation lead (Pb) isotope analyses of single ice-rafted (>150 mm) feldspar grains. To track when an ice-rafting setting consistent with major NHG first occurred in the North Atlantic Ocean during the Pliocene intensification of NHG (iNHG), we investigate when the Pb-isotope composition (206Pb/204Pb, 207Pb/204Pb, 208Pb/204Pb) of feldspars deposited at DSDP Site 611 first resembles that determined for IRD deposited at this site during MIS 100, the oldest glacial for which there exists convincing evidence for widespread glaciation of North America. Whilst Quaternary-magnitude IRD fluxes exist at Site 611 during glacials from 2.72 Ma, we find that the provenance of this IRD is not constant. Instead, we find that the Pb isotope composition of IRD at our study site is not consistent with major NHG until MIS G2 (2.64 Ma). We hypothesise that IRD deposition in the North Atlantic Ocean prior to MIS G2 was dominated by iceberg calving from Greenland and Scandinavia. We further suggest that the grounding line of continental ice on Northeast America may not have extended onto the continental shelf and calved significant numbers of icebergs to the North Atlantic Ocean during glacials until 2.64 Ma.

Study of the Mechanical Strength Improvement of Wafers for EWT Solar Cells by Chemical Etching after the Drilling Process

Mechanical stability of EWT solar cells deteriorates when holes are created in the wafer. Nevertheless, the chemical etching after the hole generation process improves the mechanical strength by removing part of the damage produced in the drilling process. Several sets of wafers with alkaline baths of different duration have been prepared. The mechanical strength has been measured by the ring on ring bending test and the failure stresses have been obtained through a FE simulation of the test. This paper shows the comparison of these groups of wafers in order to obtain an optimum value of the decreased thickness produced by the chemical etching

Effect of hole drilling at the overlap on the strength of single-lap joints

Bonded unions are gaining importance in many fields of manufacturing owing to a significant number of advantages to the traditional fastening, riveting, bolting and welding techniques. Between the available bonding configurations, the single-lap joint is the most commonly used and studied by the scientific community due to its simplicity, although it endures significant bending due to the non-collinear load path, which negatively affects its load bearing capabilities. The use of material or geometric changes in single-lap joints is widely documented in the literature to reduce this handicap, acting by reduction of peel and shear peak stresses at the damage initiation sites in structures or alterations of the failure mechanism emerging from local modifications. In this work, the effect of hole drilling at the overlap on the strength of single-lap joints was analyzed experimentally with two main purposes: (1) to check whether or not the anchorage effect of the adhesive within the holes is more preponderant than the stress concentrations near the holes, arising from the sharp edges, and modification of the joints straining behaviour (strength improvement or reduction, respectively) and (2) picturing a real scenario on which the components to be bonded are modified by some external factor (e.g. retrofitting of decaying/old-fashioned fastened unions). Tests were made with two adhesives (a brittle and a ductile one) varying the adherend thickness and the number, layout and diameter of the holes. Experimental testing showed that the joints strength never increases from the un-modified condition, showing a varying degree of weakening, depending on the selected adhesive and hole drilling configuration.

Investigation of aspect ratio of hole drilling from micro to nanoscale via focused ion beam fine milling

Holes with different sizes from microscale to nanoscale were directly fabricated by focused ion beam (FIB) milling in this paper. Maximum aspect ratio of the fabricated holes can be 5:1 for the hole with large size with pure FIB milling, 10:1 for gas assistant etching, and 1:1 for the hole with size below 100 nm. A phenomenon of volume swell at the boundary of the hole was observed. The reason maybe due to the dose dependence of the effective sputter yield in low intensity Gaussian beam tail regions and redeposition. Different materials were used to investigate variation of the aspect ratio. The results show that for some special material, such as Ni-Be, the corresponding aspect ratio can reach 13.8:1 with Cl₂ assistant etching, but only 0.09:1 for Si(100) with single scan of the FIB.

Applicazioni della tecnica di misura incremental hole drilling per provini sottili

Allo scopo di valutare le tensioni residue di un pannello in alluminio sottile, è stata sviluppata la tecnica definita Incremental Hole Drilling. Poichè tale tecnica è applicata a componenti di spessori rilevanti, per ovviare alle problematiche di vibrazione del provino è stata applicata una controlastra di resina polimerizzata per aumentare la rigidezza flessionale. Le analisi effettuate hanno mostrato una influenza della resina non trascurabile sullo stato di tensione del materiale.

Determinazione delle tensioni residue in componenti metallici sottili mediante "incremental hole drilling"

La vita di un aeromobile è un elemento importante sia per quanto riguarda la sicurezza del payload, che da un punto di vista economico, a causa delle spese di manutenzione/rinnovamento della flotta che una compagnia aerea deve affrontare. Gli elementi costitutivi di un aeromobile sono soggetti a diverse tipologie di carichi, alcuni dei quali ciclici come la pressurizzazione/depressurizzazione della fusoliera; tali carichi, nel lungo periodo, possono provocare la nascita e la propagazione di eventuali cricche, le quali possono portare alla rottura del componente stesso causando gravi incidenti. Il legame tra tensioni residue e nascita/crescita delle cricche ha portato allo sviluppo di tecniche per contrastare questo fenomeno, come il processo del LSP. Per la misura delle tensioni residue esistono già normative di riferimento, le quali però non trattano componenti metallici di piccolo spessore mentre i pannelli di fusoliera rientrano in questa categoria. Scopo di questa tesi è quello di studiare una variante della tecnica HD adatta a valutare le tensioni residue in componenti metallici di piccolo spessore e confrontare i risultati con quelli ottenuti con la tecnica XRD. L’idea di partenza è l’implementazione di un supporto posteriore in resina che simuli la presenza di uno spessore maggiore.

Eocene siliceous and calcareous phytoplankton, Deep Sea Drilling Project Holes 95-612 and 95-613

Eocene siliceous and calcareous phytoplankton, with emphasis on silicoflagellates, were studied in 62 samples from DSDP Sites 612 and 613 on the continental slope and rise off New Jersey. The mid-latitude assemblages correlate well with assemblages from California, Peru, and offshore of southern Brazil, but are distinctly different from high-latitude cold-water assemblages of the Falkland Plateau off southern Argentina. Coccoliths and silicoflagellates provide evidence for the presence of a fairly complete middle and upper Eocene sequence, represented by a composite of Sites 612 and 613. A major unconformity occurs at the middle Eocene to upper Eocene contact at Site 612. The genus Bachmannocena Locker is emended and proposed as a replacement for genus Mesocena Ehrenberg for ring silicoflagellates. Six new silicoflagellates and one new diatom are described: Bachmannocena apiculata monolineata Bukry, n. subsp., Corbisema amicula Bukry, n. sp., C. bimucronata elegans Bukry, n. subsp., C. hastata incohata Bukry, n. subsp., C. jerseyensis Bukry, n. sp., Dictyocha acuta Bukry, n. sp., and Coscinodiscus eomonoculus Bukry, n. sp. Also, one new replacement name, B. paulschulzn Bukry, nom. nov., and 24 new combinations are proposed for genus Bachmannocena.