Research on Deep-hole Drilling Quality of High-strength Steel With Slender Gun Drill

There are a lot of problems exist in the processing of long and thin deep hole gun drilling of high strength steel, such as insufficient of the machining mechanism and characteristics of gun drilling, difficulty in selecting machining parameters, unknown influence mechanism of machining parameters on drilling force, drilling temperature and machining quality. In this paper, 42CrMo high strength steel is selected as the workpiece material. A numerical model of cutting force is established based on the mechanism of gun drill, and then the finite element simulation and processing test are carried out. The results show that the cutting force decreases with the increase of cutting speed, and increases with the increase of feed speed; the error between the theoretical and actual value is less than 10%. Cutting speed and feed speed have a great influence on machining quality, and the cutting fluid pressure mainly affects the surface roughness.

Study of Double-Edged Gun Drills with Different Edge Types in Drilling Compacted Graphite Iron

Deep-hole machining is an important part in the field of mechanical processing of diesel engine. Gun drill has been widely used in deep-hole machining because of its high dimensional accuracy, high efficiency and good straightness. Through experiments on drilling compacted graphite iron with two different edge types of double-edged gun drills, the spindle power, axial force and tool wear were analyzed and found out one edge type which is more suitable for processing compacted graphite iron. This paper presents a simulation of deep hole drilling to validate the analysis. The research results have important guiding significance for deep hole processing of compacted graphite iron.

Control of Chip Formation and Improved Chip Ejection in Drilling With Modulation-Assisted Machining

Drilling with modulation-assisted machining (MAM) superimposes a low-frequency oscillation onto the drill feed motion. The otherwise continuous cutting in the drilling process is converted into a series of discrete cutting events. The result is a discrete chip formation process and concurrent improvement in chip ejection. The discrete chip formation and ejection in drilling with MAM were investigated via systematic experiments in OFHC Cu and Ti6Al4V using a two-flute twist drill and a single-flute gun drill. Drilling thrust force and chip morphologies for various modulation conditions are examined. The continuous cutting and discrete cutting regimes of modulation-assisted drilling are compared with conditions determined by a kinematic model. The results show that chip formation in the continuous cutting regime with MAM can influence chip breakage by random fracture at thin sections of the chip, but in this regime the resulting chip size is variable and not controlled. In contrast, when MAM conditions operate in the regime of discrete cutting, the deformed chip size can be directly controlled. The ability to control the chip size improves chip ejection and drilling process stability. A set of modulation conditions for enhanced performance of chip ejection are proposed. The study shows that modulation-assisted machining offers distinct advantages as a method for deep-hole drilling applications.

On the influence of thermal processes on the dynamics of a drill during deep hole machining

Deep drilling process has been studied and dynamic features of interaction the cutting part of the gun drill with the detail have been identified. Thermal processes of cutting and heat sinking in the interacting chains were analyzed: “heat source – workpiece”; “heat source - chips”; heat source – tool”; “heat source – cooling liquid”. It has been noted that the vibrations lead to the loss of dimensional accuracy of the part fabrication as well as hole surface quality. Mathematical dependence of the longitudinal and torsional oscillations of the cutting drill bit is determined and the influence of heat flow pulsations on the friction coefficients and cutting force is revealed.

Experimental Evaluation of Cutting Kinematics and Chip Evacuation in Drilling With Low-Frequency Modulation-Assisted Machining

Modulation assisted machining (MAM) superimposes a low-frequency oscillation onto the cutting process. The otherwise continuous cutting is transformed into a series of discrete, intermittent cutting events. A primary benefit of this process is to form discrete chips of small sizes and hence to improve chip evacuation. For applications in drilling the ability to control the chip size offers a direct route to improving process efficiency and stability. In this paper, the MAM process is evaluated for drilling applications via systematic experiments in drilling copper and Ti6Al4V with a two-flute twist drill and a single-flute gun drill. Based on the measurement of thrust force and examination of chip morphology, the continuous cutting and intermittent cutting regimes of MAM are determined experimentally in the normalized frequency and amplitude parameter space. The results are compared with those predicted by the kinematic model of MAM. Furthermore, the results clearly demonstrate the effect of chip morphology control on chip evacuation and process stability in drilling. The modulation conditions leading to the best performance in chip evacuation are discussed. The study shows that MAM is a promising process for enhancing the efficiency and stability in drilling difficult-to-cut materials and/or holes with high length-to-diameter ratio.