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A Mechanistic Approach to Model Cutting Forces in Drilling with Indexable Inserts
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0002-0390-9194
AB Sandvik Coromant, SE-811 81 Sandviken, Sweden.
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0001-9331-7354
2014 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 24, no 0, 74-79 p.Article in journal (Refereed) Published
Abstract [en]

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.

Place, publisher, year, edition, pages
2014. Vol. 24, no 0, 74-79 p.
Keyword [en]
Indexable insert drill, Cutting-forces, Mechanistic force model.
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
URN: urn:nbn:se:hv:diva-7025DOI: 10.1016/j.procir.2014.07.138ScopusID: 2-s2.0-84923168435OAI: diva2:765648
Knowledge Foundation

New Production Technologies in Aerospace Industry - 5th Machining Innovations Conference (MIC 2014)

Available from: 2014-11-24 Created: 2014-11-24 Last updated: 2016-02-09Bibliographically approved
In thesis
1. Dynamics of Torsional and Axial Vibrations in Indexable Drills
Open this publication in new window or tab >>Dynamics of Torsional and Axial Vibrations in Indexable Drills
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Drilling is widely used in manufacturing of products which need holes, for example for fluid channels, screws or pins. Depending on application, workpiece material, cutting parameters and economic considerations, different types of drills are employed. Indexable insert drills are types of drills which facilitate inserts to make holes. These types of drills can make high pitch noises due to vibrations. The focus of this thesis is to investigate the mechanism behind these vibrations in order to help reducing the generated noise in the future designs. Primary investigations show that the main mechanism which results the mentioned noise is regenerative chatter vibrations due to axial and torsional flexibilities. There is a gap in modeling of chatter vibrations in indexable drills where loadings and geometries are asymmetrical and due to torsional vibrations, delay terms are variable. The first step of simulating regenerative chatter vibrations in the drill is to model static cutting forces in a reliable way. In this thesis, a model is proposed which is capable of predicting static cutting forces through segmentation of cutting edges. Since, using this model, forces can be calculated separately on each insert, it is possible to consider differences of inserts in estimationof the cutting loads. The obtained loads are used in the chatter simulation.A model is proposed to simulate chatter vibrations by considering axialand angular deflections and the coupling between them. The resulted model isa system of delay differential equations with variable delays. Variations in timedelays, tool jump-outs and backward motions of inserts have been included inthe proposed time-domain simulation. A set of experiments is conducted toverify the model.

Place, publisher, year, edition, pages
Trollhättan: University West, 2015. 54 p.
Licentiate Thesis: University West, 6
Drilling Dynamics, Chatter Vibrations, Indexable Drills, Simulation
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
urn:nbn:se:hv:diva-8736 (URN)978-91-87531-23-1 (Printed version) (ISBN)978-91-87531-22-4 (Electronic version) (ISBN)
Available from: 2015-12-01 Created: 2015-12-01 Last updated: 2016-01-11Bibliographically approved

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Parsian, AmirBeno, TomasEynian, Mahdi
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