Experimental analysis of the BTA deep drilling and a new analytical thermomechanical model for assessment of cutting forces and BTA drill design

Haddag, Badis; Nouari, Mohammed; Moufki, Abdelhadi

doi:10.1007/s00170-019-04562-9

Cited by 8 publications

(7 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In this paper, the cutting force (F C ) in the X-axis direction and the axial force (Fa) in the Z-axis direction are selected as the research and analysis objects (Haddag et al, 2020). Since the cutting forces in the X-axis and Y-axis direction are all in the rule of sine and cosine, the force in the X-axis is sufficiently representative .…”

Section: The Influence Of Feed Rate and Rotation Speed On Drilling Forcementioning

confidence: 99%

Retraction: Study on straightness deviation control in the BTA deep hole drilling based on thermal-mechanical coupling simulation method

Zhu

Zhang

Li³

et al. 2021

JAMDSM

View full text Add to dashboard Cite

Nickel-based superalloys also have super high strength at high temperatures, which are typically difficult to be processed. As the material of hydraulic parts, aircraft engines, and downhole intelligent tools, it has the characteristics of large cutting deformation, severe work hardening, and low thermal conductivity in deep hole machining, which will lead to the problem of poor straightness of the deep hole. In order to solve the problem of poor straightness of the deep hole in machining nickel-based superalloys, a three-dimensional finite element model of BTA deep hole drilling based on thermal-mechanical coupling is established, and the influence of different blade angles, rotation speeds, and feed rates on drilling force is calculated. The prediction model of drilling force is obtained based on the response surface regression analysis method, and the multi-objective optimization of blade angle, rotation speed, and feed rate are carried out by using the random direction search method. The BTA deep hole drilling experiments are carried out by using the optimized tool and process parameters, and the effects of different process parameters on the straightness of the deep hole of nickel-based superalloys are analyzed. The results of the research show that: Different rotation speeds and feed rates will lead to different degrees of strain hardening and thermal softening. This will lead to a significant difference in the value of the drilling force on the tool. The straightness deviation of the deep hole in nickel-based superalloys can be controlled by optimizing the tool structure and process parameters. The research work in this paper can provide a basis for the structural design of the BTA tool and optimization of process parameters.

show abstract

Section: The Influence Of Feed Rate and Rotation Speed On Drilling Forcementioning

confidence: 99%

Retraction: Study on straightness deviation control in the BTA deep hole drilling based on thermal-mechanical coupling simulation method

Zhu

Zhang

Li³

et al. 2021

JAMDSM

View full text Add to dashboard Cite

show abstract

“…Initially, a 3D FEM simulation of a new tool was utilised for friction model identification, comprising three parameters with three levels each: A(3.4, 5, 6.6), B(20.4, 20.1, 0.2) and C(0.7, 0.9, 1.1). Fifteen parameter combinations, generated based on CCD, were introduced to the 3D FEM simulations to obtain resultant feeding forces (F a ) and torques (M c ) on the BTA drill (Figure 6(a) and (c)), expressed as equation (8). A response surface was established to associate simulation results with the friction model parameters (A, B, C).…”

Section: Finite Element Modellingmentioning

confidence: 99%

“…6 Predicting BTA drill wear evolution on an industrial deep-hole drilling machine is of great technical and economic importance for guiding tool replacement and preventing drilling defects in Inconel 625 laminate drilling processes. 7,8 Inconel 625, in comparison with mild steel, aluminium or stainless steel, is considered a difficult-to-cut material owing to its low thermal conductivity and work hardening, causing severe tool wear. 9,10 Understanding tool wear mechanisms for predicting tool life is essential.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Wear prediction of BTA drill based on finite element method for drilling laminated Inconel 625 deposited metal and FeCr alloy material

Guan

Lü

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

This study investigated the wear prediction of BTA drills for laminated Inconel 625 deposited metal and FeCr alloy materials using 3D finite element modelling. High interface temperature owing to increased cutting speed enhances the abrasive wear mechanism of Inconel 625, while FeCr alloy exhibits a predominantly adhesive wear mechanism. The interface temperature and normal pressure required as inputs for tool-wear prediction were obtained using response surface methodology (RSM), which was developed by combining the central composite design (CCD) with finite element method simulation. This approach significantly improved the computational efficiency and provides accurate predictions with the calibrated friction model. A modified Usui wear model was established considering the sensitivity of temperature to wear rate for Inconel 625. A significant improvement in prediction accuracy was observed compared with the original Usui equation. The proposed tool-wear prediction model was validated through experimental tests. The maximum predicted flank wear width deviations for the outer and intermediate edges of BTA drill were 2% and 7%, respectively. The results demonstrate the effectiveness of the proposed BTA drill wear-prediction approach for laminated materials with different wear characteristics, providing theoretical guidance for cutting-parameter optimisation and tool-replacement strategies.

show abstract

“…BTA deep hole machining is a composite-forming method of tooth cutting and guide pad extrusion. The guide pads balance the tooth cutting force, and secondary ironing on the forming hole walls of the tooth cutting is performed to realize the self-guiding of deep hole machining, thereby ensuring machining hole accuracy [ 6 , 7 , 8 ]. The mechanism of self-guiding deep hole drilling is extremely complex, which makes it difficult to accurately control the quality of BTA deep hole drilling [ 9 , 10 , 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

Analytical Model of Hole Diameter and Self-Guiding Machining Mechanism of BTA Deep Hole Drilling

Zheng

et al. 2022

Materials

View full text Add to dashboard Cite

The goal of this study was to explore the self-guided machining mechanism of boring and trepanning association (BTA) deep hole drilling and realize precise control of the machining quality. The motion analysis method was used to analyze the center motion trajectory of the drill during the entrance, and the self-guiding mechanism and hole-forming mechanism of BTA deep hole drilling were revealed. Considering the bending deformation of the drilling tube and the tool structure parameters, according to the elastic-plastic deformation theory and Hertzian contact theory, a novel analytical model of the extrusion contact between the guide pads and the hole wall of the BTA deep hole drilling was established for the theoretical prediction of the extrusion deformation and the machining hole diameter. Combined with the finite element method (FEM) simulation model, the variation law of the contact inclination angle, contact stress, and extrusion deformation of the guide pads and the hole wall with the drilling conditions were studied. The total extrusion deformation between the guide pad and the hole wall was between 10 and 50 μm. The maximum error between the FEM simulation results and the test results was 18.1%, and the maximum error between the analytical model results and the test results was 23.6%. The simulation and experimental results showed that the established extrusion contact model could accurately predict the extrusion deformation of the hole wall and the machining hole diameter.

show abstract

Experimental analysis of the BTA deep drilling and a new analytical thermomechanical model for assessment of cutting forces and BTA drill design

Cited by 8 publications

References 21 publications

Retraction: Study on straightness deviation control in the BTA deep hole drilling based on thermal-mechanical coupling simulation method

Retraction: Study on straightness deviation control in the BTA deep hole drilling based on thermal-mechanical coupling simulation method

Wear prediction of BTA drill based on finite element method for drilling laminated Inconel 625 deposited metal and FeCr alloy material

Analytical Model of Hole Diameter and Self-Guiding Machining Mechanism of BTA Deep Hole Drilling

Contact Info

Product

Resources

About