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TECHNICAL PAPERS

Modeling Chip-Evacuation Forces and Prediction of Chip-Clogging in Drilling

[+] Author and Article Information
Jeffrey C. Mellinger, O. Burak Ozdoganlar, Richard E. DeVor, Shiv G. Kapoor

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

J. Manuf. Sci. Eng 124(3), 605-614 (Jul 11, 2002) (10 pages) doi:10.1115/1.1473146 History: Received March 01, 2001; Revised December 01, 2001; Online July 11, 2002
Copyright © 2002 by ASME
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References

Kavaratzis,  Y., and Maiden,  J. D., 1990, “Real Time Process Monitoring and Adaptive Control During CNC Deep Hole Drilling,” Int. J. Prod. Res., 28, pp. 2201–2218.
White, D. M., 1999, “Intelligent Control for Agile Deep-Hole Drilling,” Master’s thesis, University of Illinois at Urbana-Champaign.
Ogawa,  M., and Nakayama,  K., 1985, “Effects of Chip Splitting Nicks in Drilling,” CIRP Ann., 34, pp. 101–104.
Kim,  J.-B., Lee,  S.-J., and Park,  Y.-P., 1994, “Development of a Drilling Process with Torque Stabilization,” J. Manuf. Syst., 13, pp. 435–441.
Nagao,  T., and Hatamura,  Y., 1994, “In-process Prediction and Prevention of the Breakage of Small Diameter Drills Based on Theoretical Analysis,” CIRP Ann., 43, pp. 85–88.
Furness,  R. J., Tsao,  T. C., Rankin,  J. S. I., Muth,  M. J., and Manes,  K. W., 1999, “Torque Control for a Form Tool Drilling Operation,” IEEE Trans. Control Syst. Technol., 7, pp. 22–30.
DeVries, M. F., and Wu, S. M., 1970, “Evaluation of the Effects of Design Variables on Drill Temperature Responses,” ASME J. Eng. Ind., pp. 699–705.
Waller,  C. E., 1966, “Some Special Equipment and Techniques Developed for the Performance Testing of Twist Drills,” CIRP Ann., 13, pp. 367–373.
Chen, Y., 1999, “Drilling Process Modeling for New Drilling Process Development,” PhD thesis, University of Michigan.
Tadmor, Z., and Gogos, C. G., 1979, Principles of Polymer Processing, John Wiley and Sons, Inc.
Darnell,  W. H., and Mol,  E. A., 1956, “Solids Conveying in Extruders,” SPE J., 12, pp. 20–29.
Broyer,  E., and Tadmor,  Z., 1972, “Solids Conveying in Screw Extruders Part 1: A Modified Isothermal Model,” Polym. Eng. Sci., 12, pp. 12–24.
Lovegrove,  J. G. A., and Williams,  J. G., 1974, “Pressure Generation Mechanisms in the Feed Section of Screw Extruders,” Polym. Eng. Sci., 14, pp. 589–594.
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Ludema, K. C., 1996, Friction, Wear, Lubrication: A Textbook in Tribology, CRC Press, Inc.
Chandrasekharan,  V., Kapoor,  S. G., and DeVor,  R. E., 1998, “A Mechanistic Model to Predict the Cutting Force System for Arbitrary Drill Point Geom-etry,” ASME J. Manuf. Sci. Eng., 120, pp. 563–570.
Spalding,  M. A., Hyun,  K. S., and Hughes,  K. R., 1997, “Stress Distributions in Solid Polymer Compacts,” J. Reinf. Plast. Compos., 16(13), pp. 1231–1240.
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Craig, Roy R., Jr., 1996, Mechanics of Materials, John Wiley & Sons, Inc.
Furness,  R. J., Ulsoy,  A. G., and Wu,  C. L., 1996, “Supervisory Control of Drilling,” ASME J. Eng. Ind., 118, pp. 10–19.
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Figures

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Typical plot of the torque varying with depth
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Typical plot of the thrust force varying with depth
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Straight-fluted drill during cutting
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Force balance on a differential section of chips
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Calibration procedure flow chart
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Chip-evacuation force for calibration test 1
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Chip-evacuation torque for calibration test 1
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Chip-evacuation force for calibration test 4
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Chip-evacuation torque for calibration test 4
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Fitted chip-evacuation forces for the calibration experiments
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Experimental and predicted chip-evacuation force for validation test 5
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Experimental and predicted chip-evacuation torque for validation test 5
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Experimental and predicted chip-evacuation force for validation test 9
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Experimental and predicted chip-evacuation torque for validation test 9
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Experimental and predicted total torque for calibration test 1
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Experimental and predicted total torque for validation test 2
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Experimental and predicted chip-evacuation force for calibration test 1
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Experimental and predicted chip-evacuation force for calibration test 3

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