Drilling Thrust and Torque Prediction of Viscoplastic Materials

2006 ◽  
Author(s):  
Hossein Vaghefpour ◽  
Ali Nayebi
Keyword(s):  
Shear Zone ◽  
Cutting Forces ◽  
Material Flow ◽  
Thrust Force ◽  
Orthogonal Cutting ◽  
Thermomechanical Properties ◽  
Twist Drill ◽  
Proposed Model ◽  
Thrust And Torque ◽  
Good Agreement

A model for drilling of viscoplastic materials is presented. An analytical model is developed for predicting thrust force and torque in the drilling with a twist drill. The thermomechanical properties are accounted for describing the material flow in the primary shear zone and at the element-chip interface. A temperature friction law is introduced. The approach is based on the representing the cutting forces along the cutting lips as a series of oblique elements. Similarly, cutting in the chisel region is treated as orthogonal cutting with different speeds depending on the radial location. The section forces obtained by the model are combined to determine the overall thrust force and drilling torque. The results of the proposed model are compared with experimental results and a good agreement is obtained.

Thermoviscoplastic modelling of drilling: Twist drills

2008 ◽  
Vol 222 (3) ◽  
pp. 403-411 ◽  
Author(s):  
A Nayebi ◽  
H Vaghefpour
Keyword(s):  
Cutting Forces ◽  
Material Flow ◽  
Thrust Force ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Thermomechanical Properties ◽  
Twist Drill ◽  
Viscoplastic Material ◽  
Al 7075 ◽  
Twist Drills

In this paper, a viscoplastic material model is proposed for drilling of metals. An analytical model is developed for predicting thrust force and torque in drilling with a twist drill. The thermomechanical properties are taken into consideration to describe the material flow in the primary shear zone and at the element—chip interface. The Johnson—Cook model is used. A temperature friction law is introduced. The approach is based on representing the cutting forces along the cutting lips as a series of oblique elements. Similarly, cutting in the chisel region is treated as orthogonal cutting with different speeds depending on the radial location. The section forces obtained by the model are combined to determine the overall thrust force and drilling torque. The results of the model are compared with the experimental results obtained by Bagci and Ozcelik in 2006 on Al 7075-T651.

The Effect of Material Flow Stress on Analytical Simulation of Machining

2010 ◽  
Vol 29-32 ◽  
pp. 1809-1814
Author(s):  
Bing Lin Li ◽  
Ling Ling ◽  
Yu Jin Hu ◽  
Xue Lin Wang
Keyword(s):  
Flow Stress ◽  
Shear Zone ◽  
Analytical Model ◽  
Material Flow ◽  
Model Simulation ◽  
Orthogonal Cutting ◽  
Shear Plane ◽  
Thermomechanical Model ◽  
Workpiece Material ◽  
Flow Stress Data

The flow stress data of the workpiece are extremely crucial for the cutting simulation. The study shows how the input data affect the analytical predictions of cutting force and temperature. The Johnson-Cook material model is used to represent workpiece flow stress in the primary shear zone. A thermomechanical model of orthogonal cutting is proposed based on the main shear plane divides the primary shear zone into two unequal parts. Five different sets of workpiece material flow stress data used in the Johnson-Cook’s constitutive equation are chosen and make the sensitivity analysis for analytical model. Simulation results were compared to orthogonal cutting test data from the available literature, and find the effects of flow stress on analytical model was different from that for finite element model.

Analysis and Validation of Cutting Forces Prediction Models in Micromachining

2006 ◽  
Vol 526 ◽  
pp. 13-18 ◽  
Author(s):  
H. Perez ◽  
Antonio Vizan Idoipe ◽  
J. Perez ◽  
J. Labarga
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Cutting Forces ◽  
Prediction Models ◽  
Precision Machining ◽  
New Model ◽  
Proposed Model ◽  
On Line ◽  
Machine Control ◽  
Good Agreement

Many investigations have been developed related to precision machining with features in the millimetre scale. In this paper different cutting force models for micromilling are analyzed and compared. A new model based on specific cutting force that also considers run-out errors has been developed. The estimated cutting forces obtained with this model had good agreement with the experimental data. Also, the proposed model allows to be implemented within the machine control for the on-line optimization of the micromilling process.

Life and Wear Prediction of Twist Drills by a Temperature Dependent Friction Law

2010 ◽  
Author(s):  
Hossein Vaghefpour ◽  
Ali Nayebi
Keyword(s):  
Material Flow ◽  
Mechanical Model ◽  
Cutting Speed ◽  
Contact Length ◽  
Temperature Dependent ◽  
Friction Law ◽  
Proposed Model ◽  
Tangential Forces ◽  
Twist Drills ◽  
Good Agreement

This paper describes the material flow in shear zone by using a thermo mechanical model. The material is an isotropic, viscoplastic rigid material; its behavior is described by a J–C law. The contact length between the chip and the tool and the temperature distribution at the tool–chip interface which has an important effect on the tool wear. Using the thermo-mechanical model and the temperature friction law, the tangential forces, friction coefficient and contact length on the cutting element as a function of radius, for different feed rate and cutting speed, are obtained. The results of proposed model are compared with experimental results and good agreement is obtained.

scholarly journals Experimental measurement of the cutting forces and wear of the drill in processing X17CrNi16-2 martensitic stainless steel

2021 ◽  
Vol 12 (1) ◽  
pp. 269-287
Author(s):  
Adrian Sorin Rosca ◽  
Nicolae Craciunoiu ◽  
Ionut Daniel Geonea ◽  
Leonard Ciurezu Gherghe
Keyword(s):  
Thrust Force ◽  
Strain Gauges ◽  
Element Analysis ◽  
Axial Thrust ◽  
Iron And Steel ◽  
Industrial Manufacturing ◽  
Analogue Signals ◽  
Acquisition Device ◽  
Thrust And Torque ◽  
Good Agreement

Abstract. For the optimum setup of an industrial manufacturing process, it can be important to know the drilling forces and moments. In many cases, theoretical estimates are not accurate enough, especially when dealing with new materials, and experimental measurements are mandatory. This paper presents the design of a dynamometer comprising a one-spoked wheel elastic component to measure the drilling thrust force and the drilling moment. A finite element analysis was made, using Ansys software, to find the most favorable position for the strain gauges. One set of strain gauges was bonded to spokes to determine the torque, and a second set was bonded to the other two spokes to quantify the axial thrust force. After dynamometer manufacturing, a calibration operation is achieved, and tests are performed by measuring the drilling forces, thrust, and torque on American Iron and Steel Institute (AISI) 1020 steel. The analogue signals from the gauges were recorded using a computer with a data acquisition device. Tool wear is studied, and the results are presented in the paper. A good agreement between results from the literature and computations demonstrates the efficiency and accuracy of this measuring instrument.

Prediction of Cutting Forces and Built-Up Edge Formation Conditions in Machining With Oblique Nose Radius Tools

1996 ◽  
Vol 210 (5) ◽  
pp. 457-469 ◽  
Author(s):  
J A Arsecularatne ◽  
R F Fowle ◽  
P Mathew ◽  
P L B Oxley
Keyword(s):  
Thermal Properties ◽  
Cutting Forces ◽  
Material Flow ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Tool Geometries ◽  
Formation Conditions ◽  
Semi Empirical ◽  
Cutting Speeds ◽  
Good Agreement

A semi-empirical machining theory is described for predicting cutting forces and temperatures for oblique nose radius tools from cutting conditions and a knowledge of work material flow stress and thermal properties. Predictions are made for a range of cutting speeds and tool geometries. It is shown how the cutting conditions giving a built-up edge can be determined from the predicted cutting temperatures. A comparison between predicted and experimental results shows good agreement.

A Modified Model of the Primary Shear Zone for Orthogonal Machining

2012 ◽  
Vol 229-231 ◽  
pp. 503-506 ◽  
Author(s):  
Fang Juan Zhou ◽  
Xue Lin Wang ◽  
Yu Jin Hu
Keyword(s):  
Stainless Steel ◽  
Shear Zone ◽  
Cutting Forces ◽  
Experimental Results ◽  
Correction Coefficient ◽  
Stainless Steel 316L ◽  
Modified Model ◽  
Orthogonal Machining ◽  
Proposed Model ◽  
Coordinate Mapping

A new modified model based on the non-parallel primary shear zone is presented in this paper. Experiments showed that the primary shear zone in cutting process wasn’t an absolutely parallel-sided zone. In fact, there are small inclined angles in the primary shear zone. Therefore, in this paper, a correction coefficient is proposed to predict cutting forces exactly. The coordinate mapping approach is adopted to obtain the correction coefficient and the software MATLAB is utilized to predict cutting forces. The material of stainless steel 316L is used to validate the modified model. By comparison between predicted analysis and experimental results, the proposed model shows good agreements with experiments.

3D FEM Simulation of Micro Cutting for Prism Patterning on Nickel Plated Roll Die Using Lagrangian Method

2012 ◽  
Vol 516 ◽  
pp. 170-175
Author(s):  
Kyung Hee Park ◽  
Dong Yoon Lee ◽  
Ki Hyeong Song ◽  
Seok Woo Lee
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Fem Simulation ◽  
Fe Model ◽  
3D Fem ◽  
Micro Cutting ◽  
Edge Wear ◽  
Good Agreement

An FE model can be usedfor better understanding the micro cutting process. To identify an edge wear effect, the cutting forces and contact stress on the cutting tool were measured as edge wear progress. On the other hand, a series of orthogonal cutting tests was also carried out forcomparisonwith FEM simulation results in termsof chip formation and cutting forces. A scanning electron microscope (SEM) was used to observe the tools and chips for the purpose of taking measurements. A Kistler dynamometer was also utilized for cutting forces measurement. The FEM micro cutting simulation showed good agreement with experimentalresults in terms of the cutting forces and chip formation. And it was observed in both FEM simulations and experiments that larger edge wear caused higher cutting forces.

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