Lightweight tooling for concentric collet drilling templates

Xiaoji Zhang; Rossitza Setchi; Khaled Giasin; Heng Gu; Quanquan Han; Michael Ryan; Andrew Hopkins

doi:10.1007/978-981-19-9205-6_8

Lightweight tooling for concentric collet drilling templates

Xiaoji Zhang, Rossitza Setchi^*, Khaled Giasin, Heng Gu, Quanquan Han, Michael Ryan, Andrew Hopkins

^*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

57 Downloads (Pure)

Abstract

This paper aims to meet clear business demand for lighter operational jigs and tools by reducing the overall weight of the concentric collet drilling templates using alternative lightweight materials and topology optimization techniques. The template structure was optimized by numerical modelling to reduce the mass and maintain relative strength. A cycle test that simulates the actual working conditions of the templates was conducted to understand the deformation and wearing during and after their usage. The simulation results indicate the challenges between reducing the mass and maintaining the stiffness of the drilling template. The hole size in each alternative aluminum template increased after 10,000 testing cycles; For harder materials like Al7075, the hardness of the borehole increased due to its high strength, to resist extending force from the collet. Whereas, for the materials with lower hardness like Al5083, the borehole hardness reduced after the cycle tests due to its low strength. The borehole surface roughness in the template increased due to wear caused by the horizontal pressure and vertical contact with the collet, which would severely increase the friction and reduce the lifetime of the template.

Original language	English
Title of host publication	Sustainable Design and Manufacturing - Proceedings of the 9th International Conference on Sustainable Design and Manufacturing SDM 2022
Editors	Steffen G. Scholz, Robert J. Howlett, Rossi Setchi
Publisher	Springer
Pages	77-87
Number of pages	11
ISBN (Electronic)	9789811992056
ISBN (Print)	9789811992049
DOIs	https://doi.org/10.1007/978-981-19-9205-6_8
Publication status	Published - 1 Jan 2023
Event	9th International Conference on Sustainable Design and Manufacturing, SDM 2022 - Split, Croatia Duration: 14 Sept 2022 → 16 Sept 2022

Publication series

Name	Smart Innovation, Systems and Technologies
Volume	338 SIST
ISSN (Print)	2190-3018
ISSN (Electronic)	2190-3026

Conference

Conference	9th International Conference on Sustainable Design and Manufacturing, SDM 2022
Country/Territory	Croatia
City	Split
Period	14/09/22 → 16/09/22

Keywords

aluminum hardness
drill jig template
friction and wearing damage

Access to Document

10.1007/978-981-19-9205-6_8

Airbus_project_paper_for_SDM2022_conference
This version of the article has been accepted for publication, after peer review (when applicable) and is subject to Springer Nature’s AM terms of use, but is not the Version of Record and does not reflect post-acceptance improvements, or any corrections. The Version of Record is available online at: http://dx.doi.org/10.1007/978-981-19-9205-6_8.
Accepted author manuscript (Post-print), 974 KB

http://sdm-22.kesinternational.org/

Cite this

Zhang, X., Setchi, R., Giasin, K., Gu, H., Han, Q., Ryan, M., & Hopkins, A. (2023). Lightweight tooling for concentric collet drilling templates. In S. G. Scholz, R. J. Howlett, & R. Setchi (Eds.), Sustainable Design and Manufacturing - Proceedings of the 9th International Conference on Sustainable Design and Manufacturing SDM 2022 (pp. 77-87). (Smart Innovation, Systems and Technologies; Vol. 338 SIST). Springer. https://doi.org/10.1007/978-981-19-9205-6_8

Zhang, Xiaoji ; Setchi, Rossitza ; Giasin, Khaled et al. / Lightweight tooling for concentric collet drilling templates. Sustainable Design and Manufacturing - Proceedings of the 9th International Conference on Sustainable Design and Manufacturing SDM 2022. editor / Steffen G. Scholz ; Robert J. Howlett ; Rossi Setchi. Springer, 2023. pp. 77-87 (Smart Innovation, Systems and Technologies).

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abstract = "This paper aims to meet clear business demand for lighter operational jigs and tools by reducing the overall weight of the concentric collet drilling templates using alternative lightweight materials and topology optimization techniques. The template structure was optimized by numerical modelling to reduce the mass and maintain relative strength. A cycle test that simulates the actual working conditions of the templates was conducted to understand the deformation and wearing during and after their usage. The simulation results indicate the challenges between reducing the mass and maintaining the stiffness of the drilling template. The hole size in each alternative aluminum template increased after 10,000 testing cycles; For harder materials like Al7075, the hardness of the borehole increased due to its high strength, to resist extending force from the collet. Whereas, for the materials with lower hardness like Al5083, the borehole hardness reduced after the cycle tests due to its low strength. The borehole surface roughness in the template increased due to wear caused by the horizontal pressure and vertical contact with the collet, which would severely increase the friction and reduce the lifetime of the template.",

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Zhang, X, Setchi, R, Giasin, K, Gu, H, Han, Q, Ryan, M & Hopkins, A 2023, Lightweight tooling for concentric collet drilling templates. in SG Scholz, RJ Howlett & R Setchi (eds), Sustainable Design and Manufacturing - Proceedings of the 9th International Conference on Sustainable Design and Manufacturing SDM 2022. Smart Innovation, Systems and Technologies, vol. 338 SIST, Springer, pp. 77-87, 9th International Conference on Sustainable Design and Manufacturing, SDM 2022, Split, Croatia, 14/09/22. https://doi.org/10.1007/978-981-19-9205-6_8

Lightweight tooling for concentric collet drilling templates. / Zhang, Xiaoji; Setchi, Rossitza; Giasin, Khaled et al.
Sustainable Design and Manufacturing - Proceedings of the 9th International Conference on Sustainable Design and Manufacturing SDM 2022. ed. / Steffen G. Scholz; Robert J. Howlett; Rossi Setchi. Springer, 2023. p. 77-87 (Smart Innovation, Systems and Technologies; Vol. 338 SIST).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

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AU - Setchi, Rossitza

AU - Giasin, Khaled

AU - Gu, Heng

AU - Han, Quanquan

AU - Ryan, Michael

AU - Hopkins, Andrew

PY - 2023/1/1

Y1 - 2023/1/1

N2 - This paper aims to meet clear business demand for lighter operational jigs and tools by reducing the overall weight of the concentric collet drilling templates using alternative lightweight materials and topology optimization techniques. The template structure was optimized by numerical modelling to reduce the mass and maintain relative strength. A cycle test that simulates the actual working conditions of the templates was conducted to understand the deformation and wearing during and after their usage. The simulation results indicate the challenges between reducing the mass and maintaining the stiffness of the drilling template. The hole size in each alternative aluminum template increased after 10,000 testing cycles; For harder materials like Al7075, the hardness of the borehole increased due to its high strength, to resist extending force from the collet. Whereas, for the materials with lower hardness like Al5083, the borehole hardness reduced after the cycle tests due to its low strength. The borehole surface roughness in the template increased due to wear caused by the horizontal pressure and vertical contact with the collet, which would severely increase the friction and reduce the lifetime of the template.

AB - This paper aims to meet clear business demand for lighter operational jigs and tools by reducing the overall weight of the concentric collet drilling templates using alternative lightweight materials and topology optimization techniques. The template structure was optimized by numerical modelling to reduce the mass and maintain relative strength. A cycle test that simulates the actual working conditions of the templates was conducted to understand the deformation and wearing during and after their usage. The simulation results indicate the challenges between reducing the mass and maintaining the stiffness of the drilling template. The hole size in each alternative aluminum template increased after 10,000 testing cycles; For harder materials like Al7075, the hardness of the borehole increased due to its high strength, to resist extending force from the collet. Whereas, for the materials with lower hardness like Al5083, the borehole hardness reduced after the cycle tests due to its low strength. The borehole surface roughness in the template increased due to wear caused by the horizontal pressure and vertical contact with the collet, which would severely increase the friction and reduce the lifetime of the template.

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Zhang X, Setchi R, Giasin K, Gu H, Han Q, Ryan M et al. Lightweight tooling for concentric collet drilling templates. In Scholz SG, Howlett RJ, Setchi R, editors, Sustainable Design and Manufacturing - Proceedings of the 9th International Conference on Sustainable Design and Manufacturing SDM 2022. Springer. 2023. p. 77-87. (Smart Innovation, Systems and Technologies). doi: 10.1007/978-981-19-9205-6_8