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Improving drilling quality for curved workpieces by contour-conforming pressing method.

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Title: Improving drilling quality for curved workpieces by contour-conforming pressing method.
Authors: Fu, Rao1,2,3 (AUTHOR), Shi, Xuepeng1,2,3 (AUTHOR), Liu, Jinlong1,2,3 (AUTHOR), Du, Changlin1,2,3 (AUTHOR), Wang, Gongshuo1,2,3 (AUTHOR) wgs1016@dlut.edu.cn, Cui, Guanping1,2,3 (AUTHOR), Zhao, Meng1,2,3 (AUTHOR)
Source: International Journal of Advanced Manufacturing Technology. Mar2026, Vol. 143 Issue 5/6, p2597-2612. 16p.
Subjects: Workpieces, Deformations (Mechanics), Drilling machines (Manufacturing), Finite element method, Machining, Compressive force
Abstract: In robotic drilling of curved workpieces, the inability of the conventional pressing method (CPM) to maintain stable contact leads to non-uniform pressure distribution, deformation and springback variations, ultimately degrading hole accuracy and machining stability. In this paper, a contour-conforming pressing method (CCPM) with curved pressure foot is developed to improve the drilling accuracy on curved workpieces. Deformation behaviors of curved workpieces with CPM and CCPM are investigated through finite element analysis. Results indicated that the CCPM achieves larger contact between pressure foot and workpiece at the initial stage of pressing, increasing the contact area and reducing stress and deformation, thereby minimizing springback and improving drilling accuracy. The effectiveness of CCPM is further validated through drilling experiments, and compared to CPM, CCPM has reduced hole roundness error by 37% and improved hole diameter accuracy by 29%. In addition, the workpiece deformation also varies with the drilling position as its stiffness changing. Experiments revealed that the impact of these stiffness-induced differences on deformation is much smaller than that caused by different pressing methods, while it will not significantly affect roundness of the drilled hole. Furthermore, the effects of pressing force under the contour-conforming pressing method on drilling quality are investigated. The pressing force was found to be a critical factor influencing drilling accuracy, as in the test conditions, the higher pressing force would lead to large workpiece deformation, resulting in Max. 0.031 mm roundness error at 750 N, and in contrast, lower pressing force would lead to instability machining, resulting in Max 0.024 mm roundness error at 150 N. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:In robotic drilling of curved workpieces, the inability of the conventional pressing method (CPM) to maintain stable contact leads to non-uniform pressure distribution, deformation and springback variations, ultimately degrading hole accuracy and machining stability. In this paper, a contour-conforming pressing method (CCPM) with curved pressure foot is developed to improve the drilling accuracy on curved workpieces. Deformation behaviors of curved workpieces with CPM and CCPM are investigated through finite element analysis. Results indicated that the CCPM achieves larger contact between pressure foot and workpiece at the initial stage of pressing, increasing the contact area and reducing stress and deformation, thereby minimizing springback and improving drilling accuracy. The effectiveness of CCPM is further validated through drilling experiments, and compared to CPM, CCPM has reduced hole roundness error by 37% and improved hole diameter accuracy by 29%. In addition, the workpiece deformation also varies with the drilling position as its stiffness changing. Experiments revealed that the impact of these stiffness-induced differences on deformation is much smaller than that caused by different pressing methods, while it will not significantly affect roundness of the drilled hole. Furthermore, the effects of pressing force under the contour-conforming pressing method on drilling quality are investigated. The pressing force was found to be a critical factor influencing drilling accuracy, as in the test conditions, the higher pressing force would lead to large workpiece deformation, resulting in Max. 0.031 mm roundness error at 750 N, and in contrast, lower pressing force would lead to instability machining, resulting in Max 0.024 mm roundness error at 150 N. [ABSTRACT FROM AUTHOR]
ISSN:02683768
DOI:10.1007/s00170-026-17544-5