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TECHNICAL PAPERS

Frequency Shift in Drilling due to Margin Engagement

[+] Author and Article Information
D. N. Dilley

Mechanical Engineering, Box 1185, Washington University, 1 Brookings Drive, St. Louis, MO 63130e-mail: dave@d3vibrations.com

D. A. Stephenson

General Motors Powertrain, Pontiac, MI 48340

P. V. Bayly

Mechanical Engineering, Box 1185, Washington University, 1 Brookings Drive, St. Louis, MO 63130

A. J. Schaut

Advanced Manufacturing R&D, The Boeing Company, St. Louis, MO

J. Manuf. Sci. Eng 127(2), 271-276 (Apr 25, 2005) (6 pages) doi:10.1115/1.1863255 History: Received February 12, 2003; Revised May 14, 2004; Online April 25, 2005
Copyright © 2005 by ASME
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References

Figures

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Experimental setup: (a) photo and (b) schematic diagram of data acquisition system
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Schematic of workpiece configuration: (a) tube drilling and (b) pilot hole in bar stock
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Waterfall plots of PSDs of force and displacement during tube drilling (margins not engaged). Setup I cutting conditions: 2 teeth, 6.35 mm tube ID, 7.62 mm tube OD, 1500 rpm, 0.05 mm/tooth feed rate, 741 Hz natural frequency of fixed-free tool. Subfigures: (a) Fξ-force parallel to cutting edge, (b) Fη-force perpendicular to cutting edge (c) Fz-thrust force, (d) ξ-displacement perpendicular to cutting edge, and (e) η-displacement perpendicular to cutting edge. Z-distance is depth into hole.
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Waterfall plots of PSDs of force and displacement during hole drilling (margins engaged). Setup I cutting conditions: 2 teeth, 6.35 mm dia pilot hole, 1500 rpm, 0.05 mm/tooth feed rate, 741 Hz natural frequency of fixed-free tool. Subfigures the same as Fig. 4. Note: scale in plots (a), (b), (c) is approximately 1 order-of-magnitude larger than in Figs. 4(a), 4(b) and 4(c).
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Stiffness factor versus depth. (a) Setup I cutting conditions: 2 teeth, 6.35 mm initial hole ID, 1500 rpm, 0.05 mm/tooth feed rate, 741 Hz natural frequency of fixed-free tool. (b) Setup II: cutting conditions: 2 teeth, 6.35 mm initial hole ID, 1500 rpm, 0.05 mm/tooth feed rate, 436 Hz natural frequency of fixed-free tool.
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Stiffness factor versus RPM. Setup I cutting conditions: 2 teeth, 6.35 and 7.62 mm initial hole ID, 0.05 mm/tooth feed rate (except at 2500 rpm there are 3 points at 0.05, 0.1, and 0.15 mm/tooth), 741 Hz natural frequency of fixed-free tool.
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Stiffness factor versus depth. Setup III: cutting conditions: 2 teeth, 9.52 mm initial hole ID, 1500 rpm, 0.05 mm/tooth feed rate, 303 Hz natural frequency of fixed-free tool
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Drill model diagrams: (a) 2-DOF rotating single-mode system and (b) simplified drill model with spring-end condition representing effects of margin engagement. Tool fixed frame: ξ-η. Space fixed frame: x-y, where z is the depth into the hole.

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