One-shot drilling of unconventional thin metal hybrid stacks for aerospace applications

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One-shot drilling of unconventional thin metal hybrid stacks for aerospace applications

PANICO Martina, D’AGOSTINO Emmanuele, DE ROSA Vincenzo, DURANTE Massimo, MESSERE Serena, LANGELLA Antonio, BOCCARUSSO Luca

Abstract. The aerospace industry’s relentless pursuit of lighter, stronger, and more fuel-efficient aircraft has led to the widespread use of lightweight materials, particularly aluminum alloys, in aerospace engineering. This study focuses on the challenges associated with one-shot drilling without back-up forces of thin parts, a strategy aimed at reducing cycle, avoiding part separation for cleaning after drilling, and minimizing part assembly problems. Despite its effectiveness, problems persist with defects developing at the interface due to the interlayer gap phenomenon. This gap causes metal chips to accumulate and is influenced by both process parameters and the clamping conditions and methodologies. While existing literature primarily associates process parameters with burr measurements, this study delves into the often-overlooked influence of clamping strategies on the occurrence of interface defects. Through experimental drilling on a thin stack of Al7075-T6 and Al2024-T3, various clamping schemes were analyzed to assess their impact on burr height. The results were also correlated with the drill verse, thrust force, and torque. The objective is to increase know-how about these aspects and optimize clamping strategies for effective one-shot drilling, addressing gaps in current research.

Keywords
One-Shot Drilling, Thin Stacked Materials, Drilling Strategy, Burr Height

Published online 4/24/2024, 10 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: PANICO Martina, D’AGOSTINO Emmanuele, DE ROSA Vincenzo, DURANTE Massimo, MESSERE Serena, LANGELLA Antonio, BOCCARUSSO Luca, One-shot drilling of unconventional thin metal hybrid stacks for aerospace applications, Materials Research Proceedings, Vol. 41, pp 2462-2471, 2024

DOI: https://doi.org/10.21741/9781644903131-271

The article was published as article 271 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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