Drilling is one of the most performed machining operations for riveting and assembly operations in many industrial sectors. The accuracy of the drilled holes and their surface finish play a vital role in the longevity and performance of the machined components, which, in turn, increase productivity. Therefore, this study investigated the effect of the multi-spindle drilling process on dimensional hole tolerances, such as hole size, circularity, cylindricity, and perpendicularity. In addition, the surface defects formed in the holes were examined using scanning electron microscopy. Three aluminium alloys, AA2024, AA6061, and AA5083, which are commonly used in the aerospace, automotive, and marine sectors, were chosen as the study materials. The results showed that the holes drilled in AA2024 gave less circularity error, cylindricity error, and perpendicularity error. In the case of hole size, the holes drilled in AA6061 were less deviated from the nominal size following holes drilled in AA2024 and AA5083 alloys. Surface damage in the form of metal debris adhesion, smeared material, side flow, and feed marks was found on the inner hole surface. Holes drilled in AA5083 alloy had the worst surface finish and were the most oversized, which was associated with noticeable damage and deformations in their inner surface. The ANOVA results revealed that the spindle speed was more influential than feed and mainly affected the hole size and cylindricity errors. However, in the case of circularity error and perpendicularity error, drilling parameters were found to be insignificant.

中文翻译：

---

评估AA5083，AA6061和AA2024的多孔钻削中的表面缺陷和尺寸公差

钻削是许多工业领域铆接和装配操作中性能最高的加工操作之一。钻孔的精度及其表面光洁度在加工零件的寿命和性能中起着至关重要的作用，从而提高了生产率。因此，本研究调查了多主轴钻孔工艺对孔尺寸公差的影响，例如孔尺寸，圆度，圆柱度和垂直度。另外，使用扫描电子显微镜检查在孔中形成的表面缺陷。选择了三种铝合金（AA2024，AA6061和AA5083）作为研究材料，它们通常用于航空航天，汽车和海洋领域。结果表明，在AA2024中钻孔的圆度误差，圆柱度误差，和垂直度误差。在孔尺寸的情况下，在AA6061和AA5083合金中钻孔后，在AA6061中钻孔比标称尺寸偏差较小。在内孔表面发现了金属碎片粘附，污迹，侧流和进给痕迹等形式的表面损坏。用AA5083合金钻的孔的表面光洁度最差，而且尺寸最大，这与内表面明显的损坏和变形有关。方差分析结果表明，主轴转速比进给更有影响力，并且主要影响孔尺寸和圆柱度误差。但是，在圆度误差和垂直度误差的情况下，发现钻孔参数不重要。与在AA2024和AA5083合金中钻孔相比，在AA6061中钻孔的名义尺寸偏差较小。在内孔表面发现了金属碎片粘附，污迹，侧流和进给痕迹等形式的表面损坏。用AA5083合金钻的孔的表面光洁度最差，而且尺寸最大，这与内表面明显的损坏和变形有关。方差分析结果表明，主轴转速比进给更有影响力，并且主要影响孔尺寸和圆柱度误差。但是，在圆度误差和垂直度误差的情况下，发现钻孔参数不重要。与在AA2024和AA5083合金中钻孔相比，在AA6061中钻孔的名义尺寸偏差较小。在内孔表面发现了金属碎片粘附，污迹，侧流和进给痕迹等形式的表面损坏。用AA5083合金钻的孔的表面光洁度最差，而且尺寸最大，这与内表面明显的损坏和变形有关。方差分析结果表明，主轴转速比进给更有影响力，并且主要影响孔尺寸和圆柱度误差。但是，在圆度误差和垂直度误差的情况下，发现钻孔参数不重要。并且在内孔表面上发现进给痕迹。用AA5083合金钻的孔的表面光洁度最差，而且尺寸最大，这与内表面明显的损坏和变形有关。方差分析结果表明，主轴转速比进给更有影响力，并且主要影响孔尺寸和圆柱度误差。但是，在圆度误差和垂直度误差的情况下，发现钻孔参数不重要。并且在内孔表面上发现进给痕迹。用AA5083合金钻的孔的表面光洁度最差，而且尺寸最大，这与内表面明显的损坏和变形有关。方差分析结果表明，主轴转速比进给更有影响力，并且主要影响孔尺寸和圆柱度误差。但是，在圆度误差和垂直度误差的情况下，发现钻孔参数不重要。