Lightweight tooling for concentric collet drilling templates

Zhang, Xiaoji, Setchi, Rossitza ORCID: https://orcid.org/0000-0002-7207-6544, Giasin, Khaled, Gu, Heng, Han, Quanquan, Ryan, Michael ORCID: https://orcid.org/0000-0002-8104-0121 and Hopkins, Andrew 2023. Lightweight tooling for concentric collet drilling templates. Scholz, Steffen, Howlett, Robert and Setchi, Rossi, eds. Sustainable Design and Manufacturing Proceedings of the 9th International Conference on Sustainable Design and Manufacturing (SDM 2022), Vol. 338. Springer, pp. 77-87. (10.1007/978-981-19-9205-6_8)

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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.

Item Type:	Book Section
Date Type:	Publication
Status:	Published
Schools:	Engineering
Publisher:	Springer
ISBN:	978-981-19-9204-9
ISSN:	2190-3018
Last Modified:	06 Jul 2023 11:01
URI:	https://orca.cardiff.ac.uk/id/eprint/156004

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