Study On Burrs And Hole Quality Of Drilling AA2024 Plates Based On FEM And Experimental Investigation

Abstract

AA2024 aluminium alloy has good resistance to fatigue crack growth, excellent damage tolerance, and high fracture toughness, so it is widely used in thin-walled structural parts. However, the excellent ductility of aluminum alloy and the weak rigidity of structural parts will lead to the questions of chip bonding, burr and machining deformation. To improve the drilling quality of the holes and the service life of the cutting tool and ensure the assembly quality and service life of the spacer frame of the passenger aircraft, the drilling experiments and thermo-mechanical coupling finite element simulation of AA2024 aluminum alloy were carried out. The effects of cutting speed and feed speed on thrust force, exit burr height, hole diameter and surface roughness were analyzed, and the empirical formulas were fitted by MATLAB. In addition, it was also found that there were three types of hole exit burr, micro exit burr or no exit burr, uniform exit burr, and exit burr cap. Finally, the drilling parameters were adjusted to vc=160 m/min and f=0.08 mm/r. Compared with the results of the original parameters, the thrust force was reduced by 31.99%, and the service life of the cutting tool was increased to 1.27 times. Moreover, the diameter accuracy and surface quality of the machined holes were also improved by 58.67% and 44.36%, respectively.

Keywords

• aa2024 aluminium alloy
• drilling experiment
• finite element simulation
• exit burrs
• hole accuracy
• surface roughness