Micro-structured Drilling Tools for Processing Lightweight Aluminum Material

Abstract

Increasing demands in production effectiveness and the growing use of high-strength aluminum alloys require tailored high-performance tooling concepts. Drilling is a major production technology and of high importance for aerospace and automotive industry.

In order to enhance the tooling performance under near-dry conditions, micro-structural patterns on the rake face have been developed systematically. Within manufacturing limitations of conventional laser systems, a CCD Design of Experiment on the determining factors of micro-structures was carried out with the purpose of optimizing the microstructural layout. Effects on chip morphology, contact condition, friction and cutting forces are studied in depth. Furthermore, capillary effects of the investigated structures could be observed. Better distribution of the lubricant on the rake face can also be held accountable for improving inprocess performance of the investigated drilling tools. The optimized micro-structured tools reduce the axial feed forces and the cutting torque by up to -25% compared to a non-structured tool.

Keywords: microstructured tools, drilling, tribology