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TECHNICAL PAPERS

Influence of Thermal Effects on Hole Quality in Dry Drilling, Part 1: A Thermal Model of Workpiece Temperatures

[+] Author and Article Information
Shiva Kalidas, Shiv G. Kapoor, Richard E. DeVor

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906

J. Manuf. Sci. Eng 124(2), 258-266 (Apr 29, 2002) (9 pages) doi:10.1115/1.1455645 History: Received October 01, 2000; Revised August 01, 2001; Online April 29, 2002
Copyright © 2002 by ASME
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References

Klocke,  F., and Eisenblatter,  G., 1997, “Dry Cutting,” CIRP Ann., 46, No. 2, pp. 1–8.
Cselle,  T., and Barimani,  A., 1995, “Today’s Applications and Future Developments of Coatings for Drills and Rotating Cutting Tools,” Surf. Coat. Technol., 76–77, pp. 712–718.
Kustas,  F., Fehrehnbacher,  L., and Komanduri,  R., 1997, “Nanocoatings on Cutting Tools for Dry Machining,” CIRP Ann., 46, No. 1, pp. 39–42.
Watanabe,  K., Yokoyuma,  K., and Ichimaya,  R., 1977, “Thermal Analyses of the Drilling Process,” Bull. Jpn. Soc. Precis. Eng. 11, pp. 71–77.
Agapiou,  J., and DeVries,  M., 1990, “On the Determination of Thermal Phenomena During Drilling-Part I: Analytical Models of Twist Drill Temperature Distributions,” Int. J. Mach. Tools Manuf., 30, No. 2, pp. 203–215.
Agapiou,  J., and DeVries,  M., 1990, “On the Determination of Thermal Phenomena During Drilling-Part II: Comparison of Experimental and Analytical Twist Drill Temperatures,” Int. J. Mach. Tools Manuf., 30, No. 2, pp. 217–226.
Fuh,  K.-H., Chen,  W.-C., and Liang,  P.-W., 1994, “Temperature Rise in a Twist Drills with a Finite Element Approach,” Int. Commun. Heat Mass Transfer, 21, No. 3, pp. 345–358.
Chao,  B., and Trigger,  K., 1951, “Cutting Temperatures and Metal Cutting Phenomena,” Trans. ASME, 73, pp. 777–793.
DeVries,  M. F., and Wu,  S., 1970, “Evaluations of the Effects of Design Variables on Drill Temperature Responses,” ASME J. Eng. Ind., 92, pp. 231–238.
Beck, J. V., Blackwell, B., and Jr., C. R. S. C., 1985, Inverse Heat Conduction Problems—Ill Posed Problems, Wiley-Interscience.
Cook, R. D., Malkus, D. S., and Plesha, M. E., 1989, Concepts and Applications of Finite Element Analysis, John Wiley & Sons.
Incropera, F. P., and DeWitt, D. P., 1996, Fundamentals of Heat and Mass Transfer, John Wiley and Sons, Fourth ed.
Dorai,  G. A., and Tortorelli,  D. A., 1997, “Transient Inverse Heat ConductionProblem Solutions via Newton’s Method,” Int. J. Heat Mass Transf., 40, No. 17, pp. 4115–4127.
Jarny,  Y., Ozisik,  M., and Bardon,  J., 1991, “A General Optimization Method Using Adjoint Equation for Solving Multidimensional Inverse Heat Conduction,” J. Heat Transfer, 34, No. 11, pp. 2911–2919.
Chandrashekran, V., 1996, “A Model to Predict Three-Dimensional Cutting Force System for Drilling with Arbitrary Point Geometry,” PhD thesis, University of Illinois at Urbana-Champaign.

Figures

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Axi-Symmetric domain shape and boundaries used in the thermal model of the workpiece
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Quantification of the thrust and torque utilized in obtaining the total energy expended at the cutting lips and chisel edge of the drill
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Workpiece geometry and thermocouple locations used in the experiments (a) and experimental setup used in obtaining workpiece temperatures and forces (b)
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Measured forces and temperatures in wet and dry drilling with HSS drills (No Coating)
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Measured temperature rise and model temperature rise profiles for test condition 1 (a), for test condition 8 (b), for test condition 9 (c) and for test condition test 11 (d)
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Predicted and measured temperature rise for validation test condition 13 (a), test condition 16 (b) and test condition 18 (c)
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Sensitivity curves at the four thermocouple locations to the heat flux at the drill margins (a), fraction of heat at the cutting lips (b) and fraction of heat at the chisel edge (c) for test condition 1 (wet conditions)
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Sensitivity curves at the four thermocouple locations to the heat flux from the drill margins (a), to the fraction of heat at the cutting lips (b) and fraction of heat at the chisel edge for test condition 5 (dry conditions)

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