A novel method for chip formation analyses in deep hole drilling with small diameters

Biermann, Dirk; Kirschner, M.; Eberhardt, D.

doi:10.1007/s11740-014-0566-7

Cited by 28 publications

(13 citation statements)

References 13 publications

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“…The utilized high-speed chip formation analysis is a newly developed method for a detailed chip formation analysis, which uses high-speed microscopy [17] . In addition to the chip formation analysis, it is also possible The investigations showed that the most favorable chips could be produced at a cutting speed of vc = 70 m/min, a feed rate of f = 0.07 mm and a cooling lubricant pressure of = 80 bar [18] , so these values were used as input data for the CFD simulation.…”

Section: Experiments Setupmentioning

confidence: 99%

Experimental and simulative investigation of the oil distribution during a deep-hole drilling process and comparing of the RANS kω-SST and RANS hybrid SAS-SST turbulence model

Oezkaya¹

2018

TSE

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Helical deep hole drilling is a process frequently used in industrial applications to produce bores with a large length to diameter ratio. For better cooling and lubrication, the deep drilling oil is fed directly into the bore hole via two internal cooling channels. Due to the inaccessibility of the cutting area, experimental investigations that provide information on the actual machining and cooling behavior are difficult to carry out. In this paper, the distribution of the deep drilling oil is investigated both experimentally and simulatively and the results are evaluated. For the Computational Fluid Dynamics (CFD) simulation, two different turbulence models, i.e. the RANS k-ω-SST and hybrid SAS-SST model, are used and compared. Thereby, the actual used deep drilling oil is modelled instead of using fluid dynamic parameters of water, as is often the case. With the hybrid SAS-SST model, the flow could be analyzed much better than with the RANS k-ω-SST model and thus the processes that take place during helical deep drilling could be simulated with realistic details. Both the experimental and the simulative results show that the deep drilling oil movement is almost exclusively generated by the tool rotation. At the tool’s cutting edges and in the flute, the flow velocity drops to zero for the most part, so that no efficient cooling and lubrication could take place there. In addition, cavitation bubbles form and implode, concluding in the assumption that the process heat is not adequately dissipated and the removal of chips is adversely affected, which in turn can affect the service life of the tool and the bore quality. The carried out investigations show that the application of CFD simulation is an important research instrument in machining technology and that there is still great potential in the area of tool and process optimization.

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Section: Experiments Setupmentioning

confidence: 99%

Experimental and simulative investigation of the oil distribution during a deep-hole drilling process and comparing of the RANS kω-SST and RANS hybrid SAS-SST turbulence model

Oezkaya¹

2018

TSE

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“…15 In addition to geometric parameters of the cutting tool, hole surface quality is also affected by the process parameters and workpiece material. 16,17 Siddiquee et al 9 optimized the process parameters (cutting fluid, speed, feed, and hole-depth) using the Taguchi method based on the evaluation of surface roughness and found that the cutting speed, cutting fluid, and feed rate make significant contributions to the machined surface quality. The process parameters, including cutting speed and feed rate, can be optimized to achieve minimum surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Experimental research on the deep-hole boring of pure niobium tube

Han

Liu

Feng

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the deep-hole boring process on pure niobium tube, there exist some problems including serious tool wear, tough chips, and poor surface quality. In order to bore high-quality deep holes on rolled niobium tube, the cutting tool structure and boring process parameters suitable for machining rolled niobium tube were designed and two experimental schemes were proposed. The results showed that the geometric parameters of the cutting tool and process parameters have important influences on the tool wear, chip morphologies, hole-axis deflection, and hole surface roughness. By adjusting the geometric parameters of the cutting tool and boring process parameters, reasonable geometric parameters of the cutting tool and boring process parameters were obtained.

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“…It is commonly applied in high-precision and high length-to-diameter ratio deep hole machining, e.g., in the fields of new energy, aerospace, and the military [3,4]. Due to the limitation of the chip removal channel area, the problem of chip breaking and evacuation is always a bottleneck in deep hole drilling, which is particularly difficult when drilling low-carbon alloy steel materials such as nuclear power tube-sheets, with strong toughness and plasticity [5][6][7][8]. In BTA deep hole drilling, if the size of the chip formation is not very regular and perfect, it might not guarantee smooth evacuation of the chip, which would lead to clogging of the chip removal channel, weakening of the cooling effect, increased drilling torque, and failure of the drill.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Chip Deformation and Breaking with a Staggered Teeth BTA Tool in Deep Hole Drilling

Zheng

et al. 2019

Metals

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The problem of chip breaking and evacuation is the key point of staggered teeth boring and trepanning association (BTA) drilling. The factors that influence chip breaking with staggered teeth BTA deep hole drilling are analyzed by using the chip bending deformation mechanism for chip formation and flow through the rake face and chip breaker. This study investigated the distribution and variation of chip deformation and breaking along drilling conditions, with respect to drilling radius, drilling process parameters, tool wear, and chip breaker geometric parameters. The results show that the tool-chip contact length is about 1.65 times the chip thickness in staggered teeth BTA drilling. The cutting radius of the teeth has a considerable influence on the chip thickness. Compared with the drilling speed, the feed has a greater impact on chip deformation and breaking, and the chip thickness and strain increase with increased feed. Increased drilling depth and tooth wear aggravates the friction state between the chip and the rake face, augments chip thickness and tool-chip contact length, and increases the chip’s strain increment. As the width of chip breaker decreases and the height increases, the chip strain increases and the breaking conditions are improved.

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A novel method for chip formation analyses in deep hole drilling with small diameters

Cited by 28 publications

References 13 publications

Experimental and simulative investigation of the oil distribution during a deep-hole drilling process and comparing of the RANS kω-SST and RANS hybrid SAS-SST turbulence model

Experimental and simulative investigation of the oil distribution during a deep-hole drilling process and comparing of the RANS kω-SST and RANS hybrid SAS-SST turbulence model

Experimental research on the deep-hole boring of pure niobium tube

Investigation of Chip Deformation and Breaking with a Staggered Teeth BTA Tool in Deep Hole Drilling

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