铝基复合材料(AMC)代表了一类创新的材料,广泛应用于汽车、防御,航空航天,结构工程,体育,和电子。这项研究调查了推力,出口毛刺形成,微型工具的变化,在铝-聚乙烯复合板(Al-PE)的微钻孔期间的钻孔直径。面板由结合到聚乙烯(PE)芯上的3501系列铝蒙皮材料组成。使用Taguchi的L16(4223)正交阵列设计了微钻孔测试参数。使用五个控制参数进行了测试:具有四个级别的切削速度(10m/min,20米/分钟,30米/分钟,40米/分钟),四个级别的进料速率(0.5µm/rev,1µm/rev,2µm/rev,4µm/rev),两个水平的刀具直径(0.7毫米,1mm),和两个水平的工具点角度(100°,140°)使用AlTiN涂层和未涂层钻头。最大推力(Fz)最大毛刺高度,测量钻具和孔直径的变化以进行方差分析(ANOVA)。结果表明,就对Fz的影响而言,工具点角度对复合材料(上铝板)入口处的微钻头的积极影响最大(64.54%)。切削速度对核心层(PE核心层)中的刀具具有最高的积极影响(45.32%)。工具点角度对复合材料下层(下铝板)的微钻头也具有最高的积极影响(68.95%)。在具有较高推力和毛刺高度的微钻孔条件下,主切削刃和鼻部区域上存在明显的切屑粘附。AlTiN涂层对刀具磨损和孔径偏差有积极影响,但它不利地影响毛刺的高度。
Aluminum Matrix Composite (AMC) represents an innovative class of materials that is extensively utilized in industries such as automotive, defense, aerospace, structural engineering, sports, and electronics. This study investigates the thrust force, exit burr formation, changes in the micro-tool, and drilled hole diameters during the micro-drilling of an aluminum-polyethylene composite panel (Al-PE). The panel consists of 3501 series aluminum skin materials bonded to a polyethylene (PE) core. Micro-drilling test parameters were designed using Taguchi\'s L16 (42 23) orthogonal array. Tests were conducted with five control parameters: cutting speed with four levels (10 m/min, 20 m/min, 30 m/min, 40 m/min), feed rate with four levels (0.5 µm/rev, 1 µm/rev, 2 µm/rev, 4 µm/rev), the tool diameter with two levels (0.7 mm, 1 mm), and tool point angle with two levels (100°, 140°) using both AlTiN-coated and uncoated drills. The maximum thrust force (Fz), maximum burr height, and changes in both the drill tool and hole diameters were measured for analysis of variance (ANOVA). The results showed that, in terms of impact on Fz, tool point angle had the highest positive influence (64.54%) on the micro-drill at the entrance of composite (upper aluminum plate). The cutting speed had the highest positive influence (45.32%) on the tool in the core layer (PE core layer). The tool point angle also had the highest positive influence (68.95%) on the micro-drill at the lower layer of the composite (the lower aluminum plate). There was noticeable chip adhesion on the major cutting edge and nose area under micro-drilling conditions with higher thrust forces and burr height. The AlTiN coating had a positive effect on tool wear and hole diameter deviations, but it adversely affected the burr height.