Drill Hole Orientation: Its Role and Importance on the Compression Response of Pure Magnesium

Featured Application Development of hybrid cellular structures for aerospace component manufacturing and repair. Drilling is used in creating cylindrical through-holes for various applications. While optimizing drilling parameters is widespread, the effect of a drilled through-hole on the structural stability of components is not fully documented. The base material, along with other parameters, such as drill diameter, drill location and its orientation affect structural stability. Since carrying out tests on different base materials can be time consuming, simulation software can instead be used to provide valuable information. However, the comparison between experiments and simulations gets difficult; hence, this study attempts to provide a basis for effective comparison by studying simulations and compression tests, comparing the two, and documenting the role of drill hole orientation on the compressive response of magnesium, a material with immense potential in light-weight components. Simulations and experiments were carried out on three through-hole orientations and were compared to the undrilled scenario. Results demonstrate significant differences in compression behaviour. While the compressive yield strength increased in all three drill orientations, ultimate strength and ductility was reduced in horizontal and angular drill hole orientations. These observations, therefore, provide valuable insight into choosing the right orientation for different applications.