Analysis of the Performance of Drilling Operations for Improving Productivity

Abstract

Drilling is a vital machining process for many industries. Automotive and aerospace industries are among those industries which produce millions of holes where productivity, quality, and precision of drilled holes plays a vital role in their success. Therefore, a proper selection of machine tools and equipment, cutting tools and parameters is detrimental in achieving the required dimensional accuracy and surface roughness. This subsequently helps industries achieving success and improving the service life of their products. This chapter provides an introduction to the drilling process in manufacturing industries which helps improve the quality and productivity of drilling operations on metallic materials. It explains the advantages of using multi-spindle heads to improve the productivity and quality of drilled holes. An analysis of the holes produced by a multi-spindle head on aluminum alloys Al2024, Al6061, and Al5083 is presented in comparison to traditional single shot drilling. Also the effects of using uncoated carbide and high speed steel tools for producing high-quality holes in the formation of built-up edges and burrs are investigated and discussed.

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
Chapter
Analysis of the Performance of
Drilling Operations for Improving
Productivity
MajidTolouei-Rad and MuhammadAamir
Abstract
Drilling is a vital machining process for many industries. Automotive and
aerospace industries are among those industries which produce millions of holes
where productivity, quality, and precision of drilled holes plays a vital role in their
success. Therefore, a proper selection of machine tools and equipment, cutting
tools and parameters is detrimental in achieving the required dimensional accuracy
and surface roughness. This subsequently helps industries achieving success and
improving the service life of their products. This chapter provides an introduction
to the drilling process in manufacturing industries which helps improve the quality
and productivity of drilling operations on metallic materials. It explains the advan-
tages of using multi-spindle heads to improve the productivity and quality of drilled
holes. An analysis of the holes produced by a multi-spindle head on aluminum
alloys Al2024, Al6061, and Al5083 is presented in comparison to traditional single
shot drilling. Also the effects of using uncoated carbide and high speed steel tools
for producing high-quality holes in the formation of built-up edges and burrs are
investigated and discussed.
Keywords: drilling, cutting tools, hole quality, productivity, multi-spindle head
. Introduction
Drilling is the most commonly performed machining operation in manufac-
turing industries. Therefore, the analysis and improvement of this process are of
great importance in increasing productivity and competitiveness, where many
existing studies reported on the optimization and improvement of this process [1,
2]. There are many machines that perform drilling operations including dedicated
drilling machines, lathes, milling machines, machining centers and special pur-
pose machines. The drilling process is extensively and heavily used in industries,
accounting for a large portion of overall machining time and costs. Therefore,
drilling has a significant economic role in industries, where it hugely contributes to
the fabrication of various industrial parts [3].
Hole-making processes using drilling operations have been the focus of many
research studies, where a lot of development and progress has been made. However,
as technology has progressed and newer tools and equipment have been introduced,
further research is required to improve the productivity and efficiency of this
important operation, which forms the core of activities in many industries [4, 5].
For example, the heat exchangers of nuclear energy centrals require up to 16,000

Drilling

holes in a single exchanger for assembly with refrigeration tubes [6]. Other examples
include the automotive industry, where the drilling process forms up to 40% of total
material removed [7], or the aerospace industry where millions of holes are required
for joining various parts of aircraft fuselage [8]. It is estimated that 750,000 holes are
required in a single wing of an Airbus A380, with 1.5–3 million holes as the require-
ments for producing a typical commercial aircraft [7]. Furthermore, over a million
rivets are needed for large ships [9] where drilling is the primary process. Therefore,
a proper selection of machine tools and equipment, cutting tools and parameters
is essential in achieving required productivity, dimensional accuracy, and surface
roughness. This subsequently helps industries achieve success and improve the
service life of their products.
. The drilling process
In the drilling process, holes are created when a cylindrical tool rotates against a
workpiece, where a tool called a drill bit is used as shown in Figure  [10, 11]. The
drilling operation process involves three stages: the start and centering stage, the
full drilling stage and the breakthrough stage [12]. In the first stage, the exact posi-
tion of the hole is required, whereas the second stage leads to the full engagement of
the drill bit, whilst the last stage includes passing the drill through the underside of
the workpiece, where the operation stops [13].
A hole in the drilling process can be created in many forms, including blind and
through holes, as shown in Figure . Blind holes are drilled to a certain depth whilst
through-holes refer to the condition when the drill bit passes through the material
and exits the workpiece on the other side [13].
Generally, a depth to diameter ratio of 5:1 or greater is commonly performed by
twist drills, where this ratio may be doubled when using high-performance twist
drills equipped with through-tool coolant systems. This ratio can be increased to
roughly 20:1 when using special deep hole drilling tools equipped with through-tool
coolant systems. Whilst this chapter focuses on the use of twist drills, it is worth-
noting that a depth to diameter ratio of 100:1 or more is achievable in gun-drilling
machines with through-tool coolant systems. Unlike conventional drilling opera-
tions, within gun-drilling machines both the cutting tool and workpiece rotate in
opposite directions and at different rotational speeds, which significantly improves
the straightness of the deep hole that is generated [14].
Figure 1.
Standard twist drill nomenclature [11].


Analysis of the Performance of Drilling Operations for Improving Productivity
DOI: http://dx.doi.org/10.5772/intechopen.96497
. Cutting conditions in drilling process
To a large extent, cutting conditions determine the success of any drilling opera-
tion. Basic cutting conditions include cutting speed, feed rate, material removal
rate, and machining time, as discussed in this section below.
. Spindle speed and cutting speed
The spindle speed is the rotational speed measured in rev/min, calculated using
a tachometer during the drilling process. The spindle speed is used to compute
desired cutting speed, defined as the distance travelled by each cutting edge on the
surface of the workpiece when cutting material. Therefore, cutting speed in a drill-
ing operation is computed by.
dn
v
p
=
1000
(1)
where
v
is the cutting speed in m/min,
p
= 3.14,
d
is the diameter of the
cutting tool in mm, and
n
is the spindle speed in rev/min.
. Feed and feed rate
In a drilling process feed is specified in mm/rev. The feed rate, which is the linear
travel rate in mm/min, can be adjusted by a convenient system when the feed is
multiplied by the spindle speed. Hence, feed rate can be found as.
r
f fn=
(2)
where r
f
is the feed rate in mm/min,
f
is the feed in mm/rev, and
n
is the
spindle speed in rev/min.
. Material removal rate
The material removal rate can be considered as an index for the determination
of the efficiency of a machining process. In a drilling process, material removal is
obtained by [15].
Figure 2.
Drilling process: (a) blind holes (b) through holes [10].

Drilling

rr r
M df
p
æö
=ç÷
èø
2
4 (3)
where
rr
M
is the material removal rate in mm3,
d
is the diameter of the drill in
mm, and
r
f
is the feed rate in mm/min.
. Drilling time
Drilling time is the time a tool is engaged from the beginning of chip produc-
tion to the end for uninterrupted machining. Any pause during this process, either
planned or unplanned, is not included in this time. The drilling time in minutes for
through holes can be determined by [15].
m
r
L
Tf
= (4)
where Tm is drilling time in minutes,
L
is the distance travelled by the cutting
tool in mm, and
r
f
is the feed rate in mm/min.
It should be noted that the drill bit should travel the distance L (see Figure ),
which consists of the desired depth of the hole plus an allowance for the tool point
angle,
A,
given by.
d
A
q
æö
=-
ç÷
èø
tan 90
22
(5)
where
A
is the allowance in mm,
d
is the diameter of the drill in mm, and
q
is
the tool point angle in degrees.
. Aluminium alloys
Aluminium and its alloys are very attractive to many manufacturing indus-
tries due to its unique combinations of properties with outstanding engineering
applications across various industries [16, 17]. Aluminium has low density, rea-
sonably high strength, high ductility, high thermal and electrical conductivities,
good oxidation and corrosion resistance, easy to manufacture and has a relatively
low cost [18].
The high strength-to-weight ratio of aluminium alloys makes them suitable for
wide use in marine, automotive and aerospace industries [19]. The various grades
of aluminium alloys used in the aviation industry can be found in reference [5].
Aluminium and its alloys are also used in home appliances, construction industries,
electrical, electronic, packaging industries, etc. [16, 19].
Aluminium alloys are divided into workable alloys and cast alloys. Alloys of
aluminium that undergo hot or cold mechanical working processes are termed as
workable alloys, while those whose shape is obtained by the casting process are
known as cast alloys [19].
Aluminium alloys are generally considered more machinable than ferrous alloys;
however, their ductile nature results in high machining forces, poor surface rough-
ness and difficult control of chips, whereas those with hard particles can cause high
tool wear [19].


Analysis of the Performance of Drilling Operations for Improving Productivity
DOI: http://dx.doi.org/10.5772/intechopen.96497
. Multi-spindle drilling for productivity improvement
Multi-spindle drilling is used in manufacturing industries to improve produc-
tivity as they can drill many holes simultaneously, which reduces machining time
significantly. The multi-spindle or poly-drill head gives high center-to-center
accuracy and in many instances eliminates the need for the use of drilling jigs,
and this further decreases drilling time and cost. Therefore, in today’s competitive
market, it is essential to produce a large number of products at the right time with
high quality and at minimum cost, where the use of a multi-spindle drill head is one
way to fulfil this goal. A multi-spindle drill head can simultaneously drill from two
to ten or more holes on the same plane [20]. The multi-spindle drill head produces
a number of holes of similar quality in the most economical way, providing a high
level of automation with a small investment [21].
Multi-spindle drilling technology is used to increase productivity whilst reduc-
ing machining time in working conditions where a large number of closely-spaced
holes need to be drilled. A good example of this is the manufacturing of aircraft
fuselage and construction of metal bridges, where a large number of riveting holes
are required. Figure  shows a section of the Golden Gate Bridge which has been
constructed using a large number of rivets. It is estimated that approximately
600,000 rivets are used in this structure [22].
Multi-spindle or poly-drill heads are mounted on a machine tool to perform
many operations simultaneously [23]. Multi-spindle drill heads are either fixed
or flexible. The tool positions in fixed multi-spindle drill heads cannot change.
Whereas in the flexible type the positions of tools can be adjusted as needed within
a particular range [24]. Figure  shows an adjustable 3-spindle drill head [25].
The importance of using this poly drill head instead of using a single drill bit is
the possibility of producing high quality drilled holes, the elimination of a drilling
jig for maintaining a high center-to-center tolerance, fewer rejections, reducing
Figure 3.
Thousands of rivets are used in the structure of the Golden Gate Bridge, San Francisco, United States.

Drilling

machining time, increasing profit rate and less operator fatigue [26]. Therefore,
it is worth noting that the use of multi-spindle drilling is an excellent choice to
improve productivity and reduce machining time for manufacturing industries
requiring the production of a large number of holes with stringent tolerances.
Therefore, the advantages of using the multi-spindle head are listed below [23]:
• The increase in productivity at a higher rate
• The performance of multiple operations in one cycle
• The time for one hole is the time for multiple numbers of holes
• The multi-spindle drilling ensures positional accuracy
• Elimination or reduction of the need for drilling jigs
• Less quality control rejections
• Easy to install and use anywhere
• Easy to operate and low maintenance
• Simple in construction and robust in design
. Cutting mechanisms in the drilling of aluminium
In the machining process, when a tool penetrates inside a metal workpiece, it
produces an internal shearing action in the metal where the metal becomes severely
stressed. This causes the metal to be plastically deformed and flow in the form of
chips when the ultimate shear strength of the metal is exceeded [27]. In the drill-
ing process, the thrust force is the perpendicular force to the workpiece during its
translational motion while the torque comes from the machine spindle to rotate the
tool during drilling operation. Other forces in drilling are not important as they are
small compared to the thrust force [28]. It should be noted that high cutting forces
affect hole quality and tool life [29]. Forces generated in the drilling of metals are
uniform where uncut chip thickness is constant [30].
Figure 4.
An adjustable 3-spindle drill head [25].


Analysis of the Performance of Drilling Operations for Improving Productivity
DOI: http://dx.doi.org/10.5772/intechopen.96497
Experimental studies have shown that thrust force generated in multi-spindle
drilling is higher than that obtained in one-shot single drilling processes of alu-
minum alloy Al5083 [31]. The higher thrust force occurs due to the combination
of more than one tool operating simultaneously in one go. However, the results of
experiments have concluded that the average of all the tools’ thrust force per tool in
multi-spindle drilling was slightly lower than the thrust force resulting from single
drilling [31]. In addition to thrust force, another important parameter in a drilling
process is the increase in cutting temperature [32]. A higher cutting temperature
increases the ductility of the material which results in the formation of long chips,
which negatively affects the hole quality [33]. A high temperature may also increase
the chemical interaction between aluminium and the tool coating that is responsible
for inter-atomic diffusion [34]. The cutting temperature increases due to heat
generation which is the result of an increase in cutting speed [35].
Further, in machining ductile materials like aluminium, there is a chance of
producing continuous chips due to the plastic deformation of its ductile nature.
Other factors that contribute to the formation of continuous chips are high cutting
speed, sharp cutting edge, etc. Continuous chips are not easy to handle and dispose
of, where they can get tangled around the tool and pose safety issues to the opera-
tor. Additionally, when a tool face is in contact for a long time, it results in more
frictional heat and affects machining. Therefore, discontinuous and segmented chips
produce less friction between the tool and chip; hence, resulting in a better surface
finish and providing higher operator safety [27].
. Cutting tool and spindle adjustment in multi-spindle drilling of aluminium
alloys
As mentioned earlier, the best performance in a drilling process is obtained
when using appropriate cutting tools, where the correct process conditions are
used to reduce the level of damage as much as possible [27]. The most commonly
used drill bit is the twist drill, as shown in Figure , which represents the industrial
standard [36]. The important features of the twist drill include the point angle,
clearance angle, chisel edge angle, drill diameter, web thickness, the rake angle,
etc. The rake angle in drills is specified as the helix angle [13]. The high point angle
and large helix angle are recommended for better hole quality and less tool wear
[37]. The large point angle also contributes to producing thinner chips during the
machining of aluminium alloys [38]. However, the point angle should be selected
based on silicon contents in aluminium alloys [39].
Experimental studies performed in references [31, 40] have shown that tools
used for multi-spindle drilling give less formation of built-up edges as compared to
the single drilling process of aluminum alloy Al5083 due to differences in chip size
when uncoated High-Speed Steel (HSS) drills with a point angle of 118° and size
of 6mm were used. The experiments were conducted using a conventional milling
machine for both single drilling and multi-spindle drilling processes, and the same
drilling parameters and conditions were applied. For the multi-spindle drilling
process, a SUNHER poly-drill head, as shown in Figure , was used.
Multi-spindle drilling experiments were further extended and uncoated HSS
drills were tested on aluminium alloy Al2024 and compared with uncoated carbide
drills with a point angle of 140° and a diameter of 6mm. Apart from aluminum alloy
Al2024, the 6mm uncoated carbide drills were also used for multi-spindle drilling
of aluminium alloys Al5083 and Al6061. In addition, 6mm uncoated carbide drills
were used to compare different center-to-center tool distances of the spindle in the
multi-spindle drilling process. Further, a comparison of 6mm and 10mm uncoated
carbide drills with the same point angle of 140° were also made [41, 42].

Drilling

In general, the uncoated carbide drill has been recommended in multi-spindle
drilling of aluminium as compared to the uncoated HSS drills due to the high
built-up edge formation because of its moderate strength, as shown in Figure . The
drill diameter did not show any significant changes in affecting the hole quality;
however, the larger drill size covered a larger cross-sectional area that resulted in
a higher thrust force and producing larger chips. Therefore, for the smaller drill
size, an easier chip breaking and evacuation was resulted. Furthermore, the larger
point angle of 140° - compared to 118° - provided a better hole quality but did not
contribute to changing the size or shape of the chips.
The tool conditions from Figure  also shows that when drilling aluminium
alloy Al5083, a large built-up edge was formed, which was expected due to low
silicon contents, where this is in agreement with research conducted by Akyüz [43]
in which alloys with low silicon contents produce a high built-up edge. Additionally,
the low hardness value of the material used in this operation might be another cause
of high formation of the built-up edge because alloys with low hardness values have
a high tendency towards the formation of built-up edges [44].
Multi-spindle drilling is useful in its easy adjustment of tools. Depending on
the type and use, the tools of a multi-spindle head can be adjusted to any position
without affecting the results, which not only increases productivity at a high rate but
also produces high-quality holes. This is performed at the same time, whereas only a
single hole is produced in one-shot single drilling process without a compromise on
the hole quality.
. Quality assessment of drilled holes in multi-spindle drilling of aluminium
In any drilling process, it is important to ensure that damage-free and precise
holes are produced to avoid rejection of parts [45]. For example, poor hole qual-
ity has been observed in 60% of aircraft components [5], which is of course a
Figure 5.
The 3-spindle Suhner multi-spindle drill head mounted on conventional milling machine (Courtesy: Edith
Cowan University, Australia).


Analysis of the Performance of Drilling Operations for Improving Productivity
DOI: http://dx.doi.org/10.5772/intechopen.96497
Figure 6.
Tool conditions after performing the drilling operation on different types of aluminium alloys using the multi-
spindle drill head.

Drilling

challenging problem. Hence, there is a need to control the number of rejected parts
by overcoming problems related to the drilling process, especially the quality of
drilled-holes [45]. A poor quality hole can create regions of concentrated stress that
increase the chances of formation of fatigue cracks, which reduces the reliability
of products [46]. Desirable hole quality in drilling operations can be achieved by
proper selection of drilling process parameters, appropriate cutting tools, and
machine setup [47].
In the experimental study by Aamir et al. [31], a single drilling process was
compared with multi-spindle simultaneous drilling of aluminium alloy Al5083
using uncoated HSS tools. The drill diameter was 6mm and the point angle was
118°. All drilling experiments were conducted using the same cutting parameters
and in a dry environment. The hole quality produced by multi-spindle drilling was
better than those obtained in a single-spindle drilling process. The holes drilled by
the multi-spindle head had a lower surface roughness and fewer burrs around the
holes. This was expected due to differences in chip formation.
Hole quality in a drilling process is also affected by the chemical composition
and mechanical properties of aluminium alloys. An experimental study in multi-
spindle drilling of aluminium alloys Al5083, Al6061, and Al2024 by Aamir et al.
[42] concluded that regardless of drilling parameters, low surface roughness was
obtained in aluminium alloy Al6061 due to its high silicon content. Literature has
shown that alloys with high silicon content result in low surface roughness irre-
spective of drilling parameters [43, 48]. Furthermore, the reason for high surface
roughness of aluminium alloy Al5083 might be due to the poor machinability and
low hardness [44].
Aamir et al. [42] observed that less burrs formed around the hole edges of
aluminium alloy Al2024 due to its good machinability compared with the alu-
minium alloys Al6061 and Al5083. Further, the less ductile nature of aluminium
alloy Al6061 - in comparison with aluminium alloy Al5083 - resulted in the low
formation of burrs. Hence, high ductility and poor machinability properties led to
the formation of more burrs in aluminium alloy Al5083 [49]. Additionally, uncoated
HSS drills produced low-quality holes by giving high surface roughness and more
formation of burrs around the edges of holes due to the high built-up edges because
of its moderate strength. Moreover, a larger point angle of 140° - compared to 118°-
and a smaller diameter of 6mm - in comparison to a drill size of 10mm – have been
recommended for multi-hole simultaneous drilling of aluminium alloys. However,
the drill diameter did not show any significant effect on hole quality including the
surface roughness and burrs [41]. Figure  shows the quality of holes in terms of
burr formation in multi-spindle drilling of aluminium alloys.
Regardless of drilling parameters, the workpiece materials and different tools,
the surface roughness increases with increasing the cutting speed and feed rate. The
likely reasons for high surface roughness at high cutting speeds might include the
increase in workpiece deformation due to rise in temperature and the chances of
high vibrations exerted by the tools [7, 47]. The high cutting speed and feed rate are
responsible for the formation of burrs that reduces the hole quality. However, the
high impact is due to the feed rate because stable, jerk-free and slow insertions of
drills are possible with low feed rates which form thin chips; hence, the hole quality
is less affected [50]. Further, according to Costa et al. [51], any factor that causes
the generation of high thrust force results in more formation of burrs, and the high
feed rate increases thrust force. Additionally, due to less formation of burrs, the tool
entry side of the holes was found to be better than those on the tool exit side. This is
likely due to the different mechanism of burr formation at the entry and exit sides
of the holes. According to Zhu et al. [52], the tearing occurs as a bending action
followed by clean shearing or lateral extrusion causing entrance burrs while exit


Analysis of the Performance of Drilling Operations for Improving Productivity
DOI: http://dx.doi.org/10.5772/intechopen.96497
burrsformed as a result of plastic deformation of the materials. Besides this, low
temperature and thrust force are the reasons for small burrs on the entry side of the
hole which can be removed by chamfering [53].
. Conclusions
Many industries, such as automotive and aerospace, produce millions of holes
per day where productivity, quality, and precision of drilled holes plays a vital role
in their success. Multi-spindle drilling is capable of producing more drilled-holes
with higher rates, which makes it advantageous in high-volume production with
uniform qualities, simultaneous machining, and most importantly reducing the
drilling time which is one of the important factors in achieving greater productivity.
Figure 7.
Hole quality in terms of burr formation in multi-spindle drilling of aluminium alloys using the multi-
spindle head.

Drilling

Author details
MajidTolouei-Rad* and MuhammadAamir
School of Engineering, Edith Cowan University, Joondalup,WA, Australia
*Address all correspondence to: m.rad@ecu.edu.au
Therefore, the production of a large number of closely-spaced holes simultaneously
by using a poly-drill or multi-spindle drill head results in achieving higher pro-
ductivity and quality. This approach not only enhances the competitiveness of the
process but also results in cost reduction and uniformity of generated holes.
Further, it can be concluded that hole quality is affected by drilling parameters
and properties of the workpiece. Alloys of aluminium with high silicon contents
show lower values of surface roughness while those with low hardness and poor
machinability provide poor hole quality. The experiments also show that uncoated
carbide tools are more suitable compared to uncoated HSS for producing high-qual-
ity holes, resulting in the formation of less built-up edges when drilling aluminium
alloys. Moreover, the aluminium alloy Al2024 produced better results in terms of
hole quality due to its good machinability compared with aluminum alloys Al6061
and Al5083.
Acknowledgements
The authors would like to thank Edith Cowan University, Australia for the
awarded (ECU-HDR) higher degree research scholarship and for providing support
on this research.
Conflict of interest
The authors declare no conflict of interest.
© 2021 The Author(s). Licensee IntechOpen. This chapter is distributed under the terms
of the Creative Commons Attribution License (http://creativecommons.org/licenses/
by/3.0), which permits unrestricted use, distribution, and reproduction in any medium,
provided the original work is properly cited.


Analysis of the Performance of Drilling Operations for Improving Productivity
DOI: http://dx.doi.org/10.5772/intechopen.96497
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