Improving the Quality of Hole Processing with a Combined Tool

Authors

  • Assylbek Kassenov Faculty of Engineering, Toraighyrov University, Pavlodar-140008, Kazakhstan
  • Aizhan Taskarina Faculty of Engineering, Toraighyrov University, Pavlodar-140008, Kazakhstan
  • Zhanara Mussina Faculty of Engineering, Toraighyrov University, Pavlodar-140008, Kazakhstan
  • Galiya Itybayeva Faculty of Engineering, Toraighyrov University, Pavlodar-140008, Kazakhstan
  • Dinara Iskakova Faculty of Engineering, Toraighyrov University, Pavlodar-140008, Kazakhstan
  • Kaіratolla Abishev Faculty of Engineering, Toraighyrov University, Pavlodar-140008, Kazakhstan
  • Leila Mussina Faculty of Engineering, Toraighyrov University, Pavlodar-140008, Kazakhstan
Volume: 15 | Issue: 3 | Pages: 22753-22761 | June 2025 | https://doi.org/10.48084/etasr.10313

Received: 22 January 2025 | Revised: 22 February 2025 | Accepted: 6 March 2025 | Online: 4 June 2025


Corresponding author: Aizhan Taskarina

Abstract

This article focused on improving the quality of hole machining using a new design of a metal-cutting tool, referred as reamer-broach. Before conducting experimental studies, fixtures were designed, a turning and screw-cutting machine was tested for geometric accuracy, and methods for evaluating the quality of the processed surface were developed. A full-factorial experiment of the 22 type was conducted to determine the influence of technological factors (rotation speed, supply) on hole accuracy, roughness, and shape deviations when machining with both a machine reamer and a reamer-broach. Additionally, an analysis of the microstructure of hole surface was performed, to prove the machinability of the material. The results indicated that an increase in feed led to an increase in the radial forces, a stabilized tool position, and a decrease in hole breakdown. An increase in rotation frequency resulted in the rise of hole breakdown as well as in an increase in surface roughness. These findings demonstrated an increase in accuracy by 1-2 quality grades compared to machine reamer and a decrease in surface roughness by 1-2 grades when processing holes using a reamer-broach.

Keywords:

reamer, broach, reamer-broach, hole, accuracy, roughness, quality

Downloads

Download data is not yet available.

References

M. Das, V. N. A. Naikan, and S. C. Panja, "A review of cutting tool life prediction through flank wear monitoring," International Journal of Quality & Reliability Management, vol. 42, no. 2, pp. 425–473, May 2024.

K. Ma, Z. Liu, B. Wang, Q. Song, and Y. Cai, "How does the uncut chip thickness affect the deformation states within the primary shear zone during metal cutting?," International Journal of Machine Tools and Manufacture, vol. 199, Jun. 2024.

Y. Guo, J. Chen, and A. Saleh, "In Situ Analysis of Deformation Mechanics of Constrained Cutting Toward Enhanced Material Removal," Journal of Manufacturing Science and Engineering, vol. 142, no. 2, Dec. 2019, Art. no. 021002.

D. Chemezov et al., "Destruction of the Billet Material During Planing.," Theoretical & Applied Science, vol. 3, no. 83, pp. 34–38, 2020.

X. Liang, Z. Liu, B. Wang, C. Wang, and C. F. Cheung, "Friction behaviors in the metal cutting process: state of the art and future perspectives," International Journal of Extreme Manufacturing, vol. 5, no. 1, Aug. 2022, Art. no. 012002.

S. N. Melkote et al., "Advances in material and friction data for modelling of metal machining," CIRP Annals, vol. 66, no. 2, pp. 731–754, Jan. 2017.

J. Loizou, W. Tian, J. Robertson, and J. Camelio, "Automated wear characterization for broaching tools based on machine vision systems," Journal of Manufacturing Systems, vol. 37, pp. 558–563, Oct. 2015.

Y. Altintas, Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, And Cnc Design, 2nd ed. Cambridge, UK: Cambridge University Press, 2012.

"Hole machining - drilling and reaming - MorekTECH," Techniki Wytwarzania i Procesy Technologiczne, Jul. 15, 2019.

Z. Ye, D. Lv, and Y. Wang, "Design of chip breaker and study on cutting performance in reaming 7050 aluminum alloy," The International Journal of Advanced Manufacturing Technology, vol. 116, no. 1, pp. 159–173, Sep. 2021.

Endwart, "Broaching: Introduction, Features, Methods, Types," Chengchun Automation Equipment, Jul. 17, 2022.

J. P. Davim, Ed., Surface Integrity in Machining. London, UK: Springer-Verlag London Limited, 2010.

V.-L. Trinh, "A Review of the Surface Roughness Prediction Methods in Finishing Machining," Engineering, Technology & Applied Science Research, vol. 14, no. 4, pp. 15297–15304, Aug. 2024.

K. A, "Precision of Hole Processing by Reamer-Broaching," Science and Technology of Kazakhstan, no. 1, pp. 28–36, 2023.

E. Y. Evseev, V. S. Kochergin, "Analysis of methods for determining cutting forces for internal broaching. Product quality: monitoring, management, improvement, planning", in Proceedings of the third International Youth Scientific and Practical Conference, 2016, pp. 252-254.

D. A. Stephenson and J. S. Agapiou, Metal Cutting Theory and Practice, 3rd ed. Boca Raton, FL, USA: CRC Press, 2018.

P. J. Arrazola, J. Rech, R. M’Saoubi, and D. Axinte, "Broaching: Cutting tools and machine tools for manufacturing high quality features in components," CIRP Annals, vol. 69, no. 2, pp. 554–577, Jan. 2020.

D. Fabre, C. Bonnet, J. Rech, and T. Mabrouki, "Optimization of surface roughness in broaching," CIRP Journal of Manufacturing Science and Technology, vol. 18, pp. 115–127, Aug. 2017.

Downloads

How to Cite

[1]
Kassenov, A., Taskarina, A., Mussina, Z., Itybayeva, G., Iskakova, D., Abishev, K. and Mussina, L. 2025. Improving the Quality of Hole Processing with a Combined Tool. Engineering, Technology & Applied Science Research. 15, 3 (Jun. 2025), 22753–22761. DOI:https://doi.org/10.48084/etasr.10313.

Metrics

Abstract Views: 37
PDF Downloads: 34

Metrics Information

License

Copyright (c) 2025 Assylbek Kassenov, Aizhan Taskarina, Zhanara Mussina, Galiya Itybayeva, Dinara Iskakova, Kaіratolla Abishev, Leila Mussina

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

Authors who publish with this journal agree to the following terms:

- Authors retain the copyright and grant the journal the right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.

- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.

- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after its publication in ETASR with an acknowledgement of its initial publication in this journal.