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TECHNICAL PAPERS

Influence of Thermal Effects on Hole Quality in Dry Drilling, Part 2: Thermo-Elastic Effects on Hole Quality

[+] 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), 267-274 (Apr 29, 2002) (8 pages) doi:10.1115/1.1458014 History: Received October 01, 2000; Revised September 01, 2001; Online April 29, 2002
Copyright © 2002 by ASME
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References

Zheng,  Y., Li,  H., Olson,  W., and Sutherland,  J., 2000, “Evaluating Cutting Fluid Effects on Cylinder Boring Surface Errors by Inverse Heat Transfer and Finite Element Methods,” ASME J. Manuf. Sci. Eng., 22, August, pp. 377–383.
Lee,  S., Eman,  K., and Wu,  S., 1987, “An Analysis of the Drill Wandering Motion,” ASME J. Eng. Ind., 109, Nov., pp. 297–305.
Fuhi,  H., Marui,  E., and Ema,  S., 1986, “Whirling Vibration in Drilling. Part 1: Cause of Vibration and Role of Chisel Edge,” ASME J. Eng. Ind., 108, Aug., pp. 157–162.
Surendran, V., 1998, “A Study of Hole Quality in Drilling,” Master’s thesis, University of Illinois at Urbana-Champaign.
Jalisi, M., Lin, C., and Ehmann, K., 1991, “Modeling and Analysis of Margin Forces in Microdrilling,” Manufacturing Processes and Materials Challenges in Microelectronic Packaging, pp. 25–33, ASME.
Watanabe,  K., Yokoyuma,  K., and Ichimaya,  R., June 1977, “Thermal Analyses of the Drilling Process,” Bull. Jpn. Soc. Precis. Eng., 11, pp. 71–77.
Stephenson, D., Barone, M., and Dargush, G., 1994, “Thermal Expansion of the Workpiece in Turning,” Materials Issues in Machining-II, Stephenson, D. and Stevenson, R., eds., pp. 257–279, ASME.
Ichimiya,  R., and Ususzaka,  Y., 1974, “Analysis of Thermal Expansion in Face Cutting Operations,” Trans. ASME, Nov., pp. 1222–1229.
Subramani, G., 1991, “Modeling of the Cylinder Boring Process for Prediction of Cutting Force, Temperature and Surface Error,” PhD thesis, University of Illinois at Urbana-Champaign.
Cook, R. D., Malkus, D. S., and Plesha, M. E., 1989, Concepts and Applications of Finite Element Analysis. John Wiley and Sons, 3rd ed.
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.
Agapiuou, J., and Stephenson, D., 1992, “Analytical and Experimental Studies of Drill Temperatures,” Materials Issues in Machining and the Physics of Machining Processes, Stevenson, R. and Stephenson, D., eds., pp. 167–186, The Minerals, Metals and Materials Society.

Figures

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Axi-Symmetric workpiece domain shape and prescribed displacement boundaries for the thermo-elastic model
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Zones of Primary and Secondary surface generation in the drilling process
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Magnified schematic representation of the deformation of the workpiece boundaries at the drill/workpiece interface
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Illustration of the nodal displacements used in obtaining relation 6
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Schematic of the measurement method used in constructing the hole profile with the aid of the CMM
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Three-dimensional rendition of the scaled error (Eq. (8)) profile obtained from drilling at 1600 rpm and 0.083 m/rev in the presence of cutting fluids (test condition 1 in Part 1)
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Variation of the average radius of the hole along the axial depth for test conducted in the presence of cutting fluids with uncoated HSS drills
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Variation of the average radius of the hole along the axial depth for test conducted in the absence of cutting fluids with uncoated HSS drills
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Variation of the average radius of the hole along the axial depth for test conducted in the absence of cutting fluids with coated carbide drills
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Measured and predicted errors in (a) the presence of cutting fluid (Test Condition #1 in Part 1) and (b) the absence of cutting fluid (Test Condition #5 in Part 1) drilled at 1600 rpm and 0.083 mm/rev with HSS drills
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Measured and predicted errors in (a) the presence of cutting fluid (Test Condition #4 in Part 1) and (b) the absence of cutting fluid (Test Condition #8 in Part 1) drilled at 2200 rpm and 0.162 mm/rev with HSS drills
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Measured and predicted errors in the absence of cutting fluid (Test Condition #7 in Part 1) drilled at 1600 rpm and 0.162 mm/rev with HSS drills
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Measured and predicted errors for dry drilling at (a) 1600 rpm and 0.083 mm/rev (Test Condition #9 in Part 1) and (b) at 2200 rpm and 0.162 mm/rev (Test Condition #12 in Part 1) with MoS2 coated carbide drills
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The development of radial errors with increasing penetration depth for test condition 5
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The development of radial errors with increasing penetration depth for test condition 8
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Distribution of workpiece temperature distribution at test condition 5 (a) and 8 (b)

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