1-s2.0-s1875389211002173-main
TRANSCRIPT
-
8/13/2019 1-s2.0-S1875389211002173-main
1/9
Available online at www.sciencedirect.com
Physics Procedia 12 (2011) 308316
1875-3892 2011 Published by Elsevier Ltd.
doi:10.1016/j.phpro.2011.03.138
LiM 2011
Analysis of the Laser Drilling Process for the Combination with a
Single-Lip Deep Hole Drilling Process with Small Diameters
Dirk Biermanna, Markus Heilmanna*
aInstitute of Machining Technology, Technische Universitt Dortmund, Baroper Str. 301, 44227 Dortmund, Germany
Abstract
Due to the tendency of downsizing of components, also the industrial relevance of bore holes with small diameters and high
length-to-diameter ratios rises with the growing requirements on parts. In these applications, the combination of laser pre-drilling
and single-lip deep hole drilling can shorten the process chain in machining components with non-planar surfaces, or can reduce
tool wear in machining case-hardened materials. In this research, the combination of these processes was realized and
investigated for the very first time.
Keywords:Hybrid machining; single-lip deep hole drilling; laser drilling; combination of drilling processes
1. Motivation / State of the Art
Because of increasing requirements on components concerning their specific properties, e. g. increasing power
density or miniaturization, the dimensions of parts diminish in size. For the production of these parts, adaptations of
the manufacturing processes used as well as the development of new technologies are necessary. This tendency is of
particular relevance in the automotive industry, the information technology industry as well as for medical and
biomedical products [1-2]. In various applications, the production of bore holes with a high length-to-diameter ratio
and small diameters is required. For the production of deep holes with small diameters different manufacturing
processes can be used. In this context single-lip deep hole drilling (SLD), laser drilling, electro discharge machining
(EDM), electron beam machining (EBM) and electro chemical machining (ECM) were used. Each of the processes
mentioned above provides specific properties, especially concerning diameter range, drilling depth, accuracy,
repeatability and process time [3-6]. The combination of different processes for bore hole production can enhance
the bore hole quality and can shorten the production time. One possibility for a hybrid process for micro machining
is the combination of laser pre-drilling and counter-boring by EDM drilling [7].
The motivation for the approach presented is based on applications, where the conditions at the beginning of the
deep hole drilling process are unfavorable. Examples are the production of deep holes in non-planar or case-
hardened surfaces [8]. In this research, the combination of the production processes laser drilling and single-lip deep
*Corresponding author. Tel.: 0049 231 755 6426; Fax: 0049 231 755 5141.
E-mail address: [email protected].
-
8/13/2019 1-s2.0-S1875389211002173-main
2/9
Dirk Biermann and Markus Heilmann / Physics Procedia 12 (2011) 308316 309
hole drilling was analyzed for the very first time. The aim of this investigation is the manufacturing of a pilot-hole
by a laser for guiding the single-lip drill (SLD) in the process phase of pre-drilling (Figure 1). With the new
approach, a reduction of the process time in machining workpieces with planar surfaces as well as a shortening of
the process chain for the production of deep holes at non-planar surfaces is intended. Furthermore, a decrease in tool
wear is aspired by laser drilling through a hardened layer. To realize these aims, an innovative machine tool concept
was developed that integrates a Nd:YAG laser for laser drilling on a conventional deep hole drilling machine tool.
Using this machine tool, the utilization of laser processes and single-lip deep hole drilling in one setup is possible.
Figure 1. Process combination of laser drilling and single-lip deep hole drilling for the production of deep holes
2. Experimental
For the experimental investigations, a prototypical machine tool was designed and built. This machine tool
consists of a Nd:YAG-laser, that is integrated into a conventional deep hole drilling machine tool for small
diameters. The results of this combination is that both, a single-lip deep hole drilling process and a laser drilling
process, can be carried out using the same machine tool and the same workpiece fixture. In this adapted machinetool, the single-lip deep hole drilling process is designed for a tool diameter range from d = 0.5 mm up to d = 6 mm.
The laser drilling process can be carried out in four different operating principles such as single-pulse, percussion,
trepanning and helical drilling. The laser used has a peak power of P = 8,000 W and a pulse duration of
t = 0.08,1 ms. The machine tool used as well as the experimental setup for laser drilling and single-lip deep hole
drilling is shown in Figure 2.
Single-Lip Deep Hole Drilling:
Borehole diameter: d = 0.5 mm up to 6 mm
Spindle power: P = 4 kW
Number of revolutions: nmax = 36.000 1/min
Feed velocity: vfmax
= 15.000 mm/min
Drilling depth: ltmax = 450 mm
TBT ML-200: Prototype Single-Lip Deep Hole Drilling Machine Tool with an Integrated Laser
Laser:
Laser power: P = 80 W
Peak power: P = 0.5,,8 kW
Peak energy: E = 0.04,,8 Joule
Pulse duration: t = 0.08,,1 ms
Figure 2. Machine tool for single-lip deep hole drilling and laser drilling
Single-lip deep hole drillingPilot -hole by laser drilling
-
8/13/2019 1-s2.0-S1875389211002173-main
3/9
310 Dirk Biermann and Markus Heilmann / Physics Procedia 12 (2011) 308316
In these experiments, for the mechanical drilling, single-lip tools with a diameter of d = 0.5 mm were chosen. The
tools consisted of a homogenous, uncoated cemented carbide substrate (ISO HW-K15) and contained an internal
cooling lubricant supply channel. As workpiece material, a stainless steel with an austenitic structure, so-called
AISI 316L, was used. The cooling lubrication concept was an internal oil supply using a high oil pressure of
p = 200 bar. The process parameters such as cutting speed and feed were varied. The range of the cutting speed was
kept between vc= 30,...,50 m/min, and the range of feed amounted between f = 0.5,...,0.7 m/rev.
3. Results and Discussion
3.1. Process design for laser pre-drilling
In the first step of the experiments conducted, the laser drilling process was analyzed with the aim of the
identification of suitable laser parameters that allow the manufacturing of bore holes meeting the requirements the
deep hole drilling process demands on a guiding assistance. The targeted pilot-hole dimensions are named in
Figure 3.
Figure 3. Definition of the targeted pilot-hole dimensions
For the guiding assistance of a single-lip deep hole drilling tool, the pilot-hole must have a diameter with a low
tolerance of dmax=500+ 10m. This tolerance is necessary to avoid the contact of the deep hole drilling tool with the
bore hole wall while moving it into the pilot-hole. Furthermore, this pilot-hole must have a low roundness deviation
to avoid contact of the cutting edge with the workpiece material during the positioning of the tool into the laser
drilled hole. The depth of the pilot-hole must be at least 1.5 of the tool diameter. This is founded in the distance of
the tool tip to the guide pad. Especially in laser drilling, a hardening at the bore hole ground and at the bore hole
wall can occur which can lead to high mechanical loads on the deep hole drilling tool. Due to that, the influence on
the peripheral zone also should be low. To fulfill these requirements, a variation of laser parameters was conducted
and the resulting bore holes were evaluated concerning the targeted values diameter, roundness deviation, drilling
depth, surface roughness and peripheral zone. For every laser parameter combination repetitions were performed to
analyze the repeatability of the laser processes. At first the laser drilling strategies single-pulse, percussion and
helical drilling were realized. The influence of the laser drilling strategy on the bore hole diameter is shown in
Figure 4.
The results show, that the use of percussion laser drilling is unsuitable for the production of laser pilot holes
under the conditions viewed. The diameter is significantly lower as the targeted value and the bore hole shows a
high roundness deviation. This is based on the higher amount of material molten by the laser. A part of this material
Target values:
Pilot-hole diameter: D = 500,,510 m
Pilot-hole depth: l = 0.75,,1.5 mm
Roundness dev.: tk < 10 m
1.53xd
d+0.01
Definition of targeted pilot-hole dimensions
-
8/13/2019 1-s2.0-S1875389211002173-main
4/9
Dirk Biermann and Markus Heilmann / Physics Procedia 12 (2011) 308316 311
solidifies at the bore hole wall before it exists the bore hole, recast-layers occurs. These layers reduce the bore hole
diameter and influence the roundness of the bore hole negatively. This effect also occurs in helical laser drilling. In
contrast to percussion drilling, the bore hole diameter can be adjusted by an adaption of the diameter of the helix D H.
Due to the creation of recast layers, the reproducibility of the diameter is lower than in single-pulse drilling. Another
disadvantage is the longer process time. In single-pulse laser drilling, the aimed diameter is approximately reached
with the laser parameters presented. Furthermore, the bore holes produced show qualitatively a high accuracy. Incombination with the shorter production times the single-pulse laser drilling was identified as the most convenient
laser drilling strategy for the production of pilot holes. Because of that, this strategy is viewed in the following.
Figure 4. Influence of the laser drilling strategy on the bore hole diameter
In the single-pulse laser drilling experiments conducted, the variables pulse duration and peak power have shown
the highest impact on the bore hole quality. Because of that, in the following the influence of these parameters will
be discussed. As named before, the main requirement of a pilot-hole for the guiding assistance of a deep hole
drilling tool is its diameter and roundness accuracy (Figure 5).
The increasing pulse duration shows the tendency of leading to growing bore hole diameters and to decreasing
roundness deviations. Due to absorption, reflection and heat transportation effects, the laser influenced area
increases and the diameter increases when using longer pulse durations. In the parameter range viewed, the impact
of the pulse duration on the roundness deviation is reciprocally to its effect on the diameter. In the experiments with
the lowest pulse duration the highest roundness deviations result. Furthermore, the scanning electron microscopy
views of the bore holes produced using the lowest pulse duration show a significant deviation of the bore hole
cylindricity. This deviation can lead to a contact of the single-lip deep hole drilling tool with the bore hole wall in
the process phase of positioning the deep hole drilling tool in the pilot hole. This contact can effect tool wear or tool
200 m 200 m 200 m 200 m 200 m
Laser: Nd:YAG Workpiece material: AISI 316L
Peak power: P = 7000 W Pulse duration: = 1 ms
Pulse frequency: f = 10 Hz Number of pulses: n = varied
Focus position: sf = 0 mm Process gas: Compr. air
200
300
400
m
600
Percussion
drilling
Helical drilling
DH = 0.1 mm
Helical drilling
DH = 0.2 mm
Helical drilling
DH = 0.25 mm
Single-pulse
drilling
Percussion / helical drilling
Number of pulses: n = 250
DiameterD
-
8/13/2019 1-s2.0-S1875389211002173-main
5/9
312 Dirk Biermann and Markus Heilmann / Physics Procedia 12 (2011) 308316
Figure 5. Influence of the pulse duration and peak power on the diameter and the roundness deviation
breakages in the area of the cutting edge corner. The occurring deviation can be explained by the Gaussian-shaped
distribution of intensity. At low pulse durations, the energy of the laser is only at the center of the laser beam
sufficient for material ablation. Due to effects leading to a loss of power, such as reflection, this area is reduced by
increasing drilling depth and the conical bore hole shape is created.
The peak power shows also an impact on the bore hole diameter. With increasing peak power, the diameter also
increases. Based on effects such as absorption, heat transportation and reflection with higher peak power thediameter also increases.
Beside the bore hole diameter and roundness deviation, the pulse duration shows an influence on the drilling
depth. This is presented in Figure 6. In the realized pulse duration range, the drilling depth increases degressively.
Due to that, the ablation rate decrease with the drilling process progress. This can also be explained by the Gaussian-
shaped distribution of intensity. Furthermore, the radiation incidence angle increase because of the conical shape of
the bore hole occurring in the laser drilling process and the connected change in absorption conditions. Another
aspect can be a plasma resulting from the vaporized metal. This plasma can absorb the laser light [10, 11].
= 0.5 ms= 0.25 ms
P=8000W
= 1 ms
P=6000W
P=7000
W
Laser: Nd:YAG Workpiece material: AISI 316L
Peak power: P = varied Pulse duration: = varied
Pulse frequency: - Number of pulses: n = 1
Focus position: sf = 0 mm Process gas: Compr. air
200 m 200 m 200 m
200 m 200 m 200 m
200 m 200 m 200 m
D = 526 m
D = 505 m
D = 493 m
D = 455 m
D = 448 m
D = 435 m
D = 507 m
D = 489 m
D = 480 mtk= 39 m tk= 15 m tk= 29 m
tk= 42 m tk= 12 m tk= 22 m
tk= 28 m tk= 20 m tk= 24 m
-
8/13/2019 1-s2.0-S1875389211002173-main
6/9
Dirk Biermann and Markus Heilmann / Physics Procedia 12 (2011) 308316 313
Figure 6. Influence of the pulse duration and the peak power on the drilling depth
Beside the requirements on the geometric tolerances of the bore hole, the pilot-hole produced by laser should also
have a low surface roughness as well as no significant impact on the peripheral zone. For the evaluation of these two
bore hole properties, cross-sections of the bore holes were produced. The surface roughness was detected using the
3D-confocal whitelight microscopy. For the evaluation of the impact of the laser drilling process on the peripheral
zone, microhardness was measured in the peripheral zone with defined distances to the bore hole wall. The results of
this analysis are presented in Figure 7.
Figure 7. Influence of the pulse duration and the peak power on the surface quality and the impact on the peripheral zone
In the laser drilling experiments using single-pulse laser drilling, a high surface quality was reached. In these
experiments, the peak power shows no influence on the surface quality but the pulse duration does. Due to the
higher drilling depth reached at higher pulse durations, more material must come out of the bore hole at increasing
0
1
mm
3
0 0.25 0.5 ms 1
Drillingdepthlt
Pulse duration
lt /
Drillingdepthlt
Laser: Nd:YAG Workpiece material: AISI 316L
Peak power: P = varied Pulse duration: = varied
Pulse frequency: - Number of pulses: n = 1
Focus position: sf = 0 mm Process gas: Compr. air
P = 7000 W
0
1
mm
3
0 6000 7000 W 9000
Peak power P
= 0.5 ms
Laser: Nd:YAG Workpiece material: AISI 316L
Peak power: P = varied Pulse duration: = variedPulse frequency: - Number of pulses: n = 1
Focus position: sf = 0 mm Process gas: Compr. air
0.0
0.10.2
0.3
0.4
0.5
m
0.7
0.0
0.51.0
1.5
2.0
2.5
m
3.5
= 0.5 ms
P = 7000 W
= 0.5 ms
P = 8000 W
= 1.0 ms
P = 8000 W
Ro
ughnessdepthRz
RoughnessRa
200
240
280
320
HV0.05
400
0 60 120 m 240
MicrohardnessHm
= 1.0 ms
P = 8000 W
Distance to the bore hole surface s
Rz
Ra
Surface quality Peripheral zone
-
8/13/2019 1-s2.0-S1875389211002173-main
7/9
314 Dirk Biermann and Markus Heilmann / Physics Procedia 12 (2011) 308316
distances. Both facts benefit the formation of recast-layers that influences the surface quality negatively. In
comparison to percussion drilling, in single-pulse drilling this effect is significantly lower. Furthermore, the standard
deviation of the surface quality reached is relatively high. Based on the assumption that high values for surface
roughness correlates with recast-layers, for the laser drilling process with the highest surface roughness,
microhardness of the peripheral zone was measured. The measurements show no significant influence of the laser
drilling process on the peripheral zone. The microhardness values detected alternate in the area of the hardness ofthe material tested.
The experiments have shown that the production of bore holes for the use as a guiding assistance for deep hole
drilling tools by laser is possible. For the aimed manufacturing task single-pulse laser drilling is the most applicable
laser drilling strategy. To fulfill the requirements on the bore hole quality, an analysis of the influences of the laser
parameters were done. With a peak power of P = 8,000 W, pulse durations between = 0.51 ms and compressed
air as process gas, bore holes can be produced meeting all requirements on a guiding assistance for single-lip deep
hole drilling. Only the roundness deviation is on a higher level than the targeted values.
3.2. Combination of laser drilling and single lip deep hole drilling
After the identification of suitable process parameters for laser drilling, the combination of laser and single-lip
deep hole drilling was done. Therefore, pilot-holes were produced using the laser parameter combinations allowingthe production of bore holes meeting the named requirements. After the production of the pilot-holes, the single-lip
deep hole drilling process was performed using the same fixture. For the pre-drilling process an adapted strategy
was necessary. To avoid a deflection of the asymmetric tool when rotating it, the tool was driven into the pilot-hole
at a low spindle speed of n = 3,000 min-1. The feed motion was stopped at a distance from the base of the pilot-hole
of s = 0.3 mm. At this position the spindle speed was increased up to n = 25,465 min-1
which corresponds to a
cutting speed of vc= 40 m/min and the targeted feed velocity was started. The tool life reached with these cutting
parameters is comparable to the tool life travel path reached in the single-lip deep hole drilling process using a
boring bush. Furthermore, the bore hole quality reached in the process combining laser and single-lip deep hole
drilling is also comparable to the conventional process. This is shown on the example of the surface quality after
laser drilling and after single-lip deep hole drilling (Figure 8).
The surface roughness reached by laser pilot drilling amounts to Rz = 1.72 m for the laser parameters used.
After the drilling experiments, a surface roughness of Rz = 1.43 m was measured in the area where the laser pilot-
hole was. The single-lip drill smoothed the surface created by laser drilling. This can also be seen in the SEM-views
presented. In the phase of positioning the deep hole drilling tool into the laser drilled pilot-hole the cutting edge
corner of the deep hole drilling tool removes surface irregularities coming from the laser drilling process.
Furthermore, the guide pad of the single-lip deep hole drilling tool smoothened the bore hole surface of the pilot-
hole at the beginning of the deep hole drilling process. Here, the occurring radial forces are supported by the guide
pad to the bore hole wall and effects an smoothening of the bore hole surface. The surface roughness reached in the
area of the pilot-hole corresponds to the value reached in the deep hole drilling process at higher drilling depths. The
combination of laser drilling and single-lip deep hole drilling has no influence of the surface quality of the bore
holes produced.
The work done presents a new technique for the production of deep holes with small diameters. Based on the
process combination of laser drilling and single-lip deep hole drilling the process specific disadvantages of bothprocess can be eliminated. With this combination, bore holes with a high length-to-diameter ratio can be produced
by a high accuracy in comparatively short process times. The feasibility of the process combination is presented in
this work and provides the opportunity for machining workpieces with non-planar faces. Here, a process time
reduction can be reached in comparison to conventional process chains consisting of a face milling, a pre-drilling
and a deep hole drilling process. In addition, tool wear can be reduced in machining case-hardened workpieces.
Here, the laser ablates the hardened material and the mechanical drill only works in the softer material.
-
8/13/2019 1-s2.0-S1875389211002173-main
8/9
Dirk Biermann and Markus Heilmann / Physics Procedia 12 (2011) 308316 315
Figure 8. Comparison of surface quality in laser pre-drilling and single-lip deep hole drilling
4. Conclusions
In the investigations carried out a combination of laser pre-drilling and single-lip deep hole drilling with a tool
diameter of d = 0.5 mm was realized for the very first time. Main requirements on the laser pre-drilling are the
diameter, the roundness deviation, the surface integrity as well as a low impact on the peripheral zone of the bore
hole. In comparison to the laser drilling strategies percussion and helical drilling it has been shown, that single-pulselaser drilling is the most applicable strategy for the production of pilot holes under consideration of the experimental
boundaries used. In single-pulse drilling, the pulse duration and the peak power has shown the highest impact on
bore hole quality. With an adaption of the laser parameters it is possible to produce bore holes which are suitable for
the use as a guiding assistance in single-lip deep hole processes. It has been proved that the combination of these
two processes is comparable to conventional deep hole drilling processes using a boring bush as guiding assistance
with respect to tool life and bore hole quality.
In future, the process combination presented will be adapted for machining workpieces with non-planar surfaces
as well as for machining case-hardened workpieces. In conclusion, the feasibility of the combination of laser pre-
drilling and single-lip deep hole drilling has been demonstrated in this research. This technique provides the
opportunities to shorten the process chain of milling, pre-drilling and deep hole drilling in machining components
with non-planar surfaces as well as to reduce tool wear in machining case-hardened workpieces.
0.0
0.1
0.2
0.3
0.4
0.5
m
0.7
0.0
0.5
1.0
1.5
2.0
2.5
m
3.5
Single-pulse laser drillingDeep hole drilling
Bore hole entrance
Deep hole drilling
Bore hole exit
RoughnessdepthRz
RoughnessRa
c = 0.08 mm
500 m
Laser: Nd:YAG Tool: Single-lip drill, d = 0.5 mm
Peak power: P = 8,000 W Cutting speed: vc = 40 m/min
Pulse duration: = 0,5 ms Feed rate: f = 0.5 m/rev.
Number of pulses: n = 1 Drilling depth: lt = 12.5 mm
Focus position: sf = 0 mm Cooling lubricant: Oil
Process gas: Compr. air Coolant pressure: p = 200 bar Workpiece material: AISI 316L
Rz
Ra
-
8/13/2019 1-s2.0-S1875389211002173-main
9/9
316 Dirk Biermann and Markus Heilmann / Physics Procedia 12 (2011) 308316
Acknowledgement
This work was supported by the German Research Foundation (DFG) under the grant We 1723/78.
References
81] Alting, L.; Kimura, F.;, Hansen, H. N.;, Bissacco, G.: Micro Engineering. In: CIRP Annals Manufacturing Technology, Vol.52, No. 2
(2003), 635-657.
[2] Weule, H.; Fleischer, J.; Buchholz, C.; Tritschler, H.; Elsner, J.; Knoll, M. et. al.: International state of the art of micro production
engineering. In: Production Engineering, Research and Development, Vol.11, No. 1 (2004), 29-36.
[3] Yu, Z. Y.; Zhang, Y.; Li, J., Luan, F.; Guo, D.: High aspect ratio micro-hole drilling aided with ultrasonic vibration and planetary movement
of electrode by micro-EDM. In: CIRP Annals Manufacturing Technology, Vol.59, No. 1 (2009), 213-216.
[4] Ali, S.; Hinduja, S.; Atkinson, J.; Pandya, M.: Shaped tube electrochemical drilling of good quality holes. In: CIRP Annals Manufacturing
Technology, Vol.59, No. 1 (2009), 185-188.
[5] Heisel, U.; Stortchak, M.; Eisseler, R.: Determination of cutting parameters in deep hole drilling with single-fluted gun drills of smallest
diameters. In: Production Engineering, Research and Development, Vol.10, No. 1 (2003), 51-54.
[6] Hung, J. C.; Lin, J. K.; Yan, B. H.; Liu, H. S.; Ho, H. P.: Using a helical micro-tool in micro-EDM combined with ultrasonic vibration for
micro-hole machining. In: Journal of Micromechanics and Microengineering, Vol.16, No. 12 (2006), 2705-2713.
[7] Li, L.; Diver, C.; Atkinson, J.; Giedl-Wagner, R.; Helml, H.J.: Sequential Laser and EDM Micro-drilling for Next Generation Fuel InjectionNozzle Manufacture. In: CIRP Annals Manufacturing Technology, Vol.55, No. 1 (2006), 179-182.
[8] Weinert, K.; Lbbe, H.: Crankshaft manufacturing on machining centres. In: Proceedings of the AMST'02, 6th International Conference, Vol.
437 (2002), 129-135.
[9] Sakuma, K.; Taguchi, K.; Katsuki, A.; Takeyama, H.: Self-guiding action of deep-hole-drilling tools. In: CIRP Annals Manufacturing
Vol.30, No. 1, 311-315.
[10] Dausinger, F.: Przisionsbohren mit kurzen und ultrakurzen Laserpulsen. In: Laser Technik Journal, No. 1 (2004), pp. 40-44
[11] Honer, M.: Prozesssicherungsmanahmen beim Bohren metallischer Werkstoffe mittels Laserstrahlung. PhD-Thesis, Universitt Stuttgart,
Herbert Utz Verlag, Mnchen, 2004