A Mechanistic Approach to Model Cutting Forces in Drilling with Indexable Inserts

Abstract

Holes are made in many industrial parts that need screws, pins or channels for passing fluids. The general method to produce holes in metal cutting is by drilling operations. Indexable insert drills are often used to make short holes at a low cost. However, indexable drills are prone to vibrate under certain circumstances, causing vibrations that affect tool life. Therefore, a good prediction of cutting-forces in drilling is important to get a good description of the cutting process for optimization of tool body and insert design. Reliable simulations of dynamic forces also aid in prediction of chatter vibrations that have significant effects on the quality of the manufactured parts as well as the tool life. In this paper, a mechanistic approach is used to model the cutting-forces. Cutting-force coefficients are identified from measured instantaneous forces in drilling operations. These coefficients are used for simulating torque around drill-axis, axial force and cutting-forces in the plane perpendicular to drill-axis. The forces are modeled separately for peripheral and central insert, which results in a detailed description of the cutting-forces acting on each insert. The forces acting on each insert are estimated by dividing the cutting edges into small segments and the cutting-forces acting on each segment are calculated. The total forces are predicted by summation of the forces acting on each segment. Simulated torque and forces are compared to measured cutting-forces for two different feeds. A good agreement between predicted and experimental results, especially in torque and axial-force, is observed.

Chip Formation in Drilling

“…The strain curve of the alloy is described by the Johnson-Cook model [1]. The tool is a helical stainless-steel bit (diameter 10 mm), with the following parameters: inclination of chip channels 30°; vertex angle 118°; core thickness 2 mm.…”

“…A mechanistic approach was adopted in predicting the cutting force in drilling in [1]. The same approach was applied to the drilling of aluminum in [2].…”

Modified Mechanistic Model Based on Gaussian Process Adjusting Technique for Cutting Force Prediction in Micro‐End Milling

“…In order to improve productivity and quality at a lower cost in micro-end-milling process, accurate and reliable predictive models of the mechanics and dynamics of microend-milling process become necessary. In micro-end-milling process, the machine and tool deflect based on the behavior of cutting forces, which impacts the geometrical accuracy 2 Mathematical Problems in Engineering of the processing feature, and the scientific prediction of cutting force can not only optimize cutting parameters and ensure the accuracy of processing but extend tool life [9]. Researchers have used artificial intelligence techniques and statistical methods to predict cutting force.…”

Use of the energy of parametric oscillations to improve drilling indices

“…Authors of papers (Chernin, Vilnay, & Shufrin, 2016;Eren & Kok, 2018;Khajiyeva, Kudaiber-genov, & Kudaibergenov, 2018) discuss drilling problems concerning vibration modeling in the context of the available drilling techniques, such as drilling deflection and use of vibration borehole tools. Paper (Parsian, Magnevall, Beno, & Eynian, 2014) considers torsion-axial engagement; the author proposes model of time domain to model vibration oscillations. The obtained model is a system of differential equations.…”