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TECHNICAL PAPERS

Modeling and Prediction of Hole Profile in Drilling, Part 1: Modeling Drill Dynamics in the Presence of Drill Alignment Errors

[+] Author and Article Information
Khagendra Gupta, O. Burak Ozdoganlar, 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 125(1), 6-13 (Mar 04, 2003) (8 pages) doi:10.1115/1.1536932 History: Received October 01, 2001; Online March 04, 2003
Copyright © 2003 by ASME
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References

Watson,  A. R., 1985, “Drilling Model for Cutting Lip and Chisel Edge and Comparison of Experimental and Predicted Results. I-Initial Cutting Lip Model,” Int. J. Mach. Tool Des. Res., 25(4), pp. 347–365.
Watson,  A. R., 1985, “Drilling Model for Cutting Lip and Chisel Edge and Comparison of Experimental and Predicted Results. II-Revised Cutting Lip Model,” Int. J. Mach. Tool Des. Res., 25(4), pp. 367–376.
Watson,  A. R., 1985, “Drilling Model for Cutting Lip and Chisel Edge and Comparison of Experimental and Predicted Results. III-Drilling Model for Chisel Edge,” Int. J. Mach. Tool Des. Res., 25(4), pp. 377–392.
Watson,  A. R., 1985, “Drilling Model for Cutting Lip and Chisel Edge and Comparison of Experimental and Predicted Results. IV-Drilling Tests to Determine Chisel Edge Contribution to Torque and Thrust,” Int. J. Mach. Tool Des. Res., 25(4), pp. 393–404.
Chandrasekharan,  V., Kapoor,  S. G., and DeVor,  R. E., 1998, “A Mechanistic Model to Predict the Cutting Force System for Arbitrary Drill Point Geometry,” ASME J. Manuf. Sci. Eng., 120(3), pp. 563–570.
Sriram, R., 1996, “An Investigation of the Effect of Radial Forces in Drilling,” Master’s thesis, University of Illinois at Urbana-Champaign, Urbana-Illinois.
Fujii,  H., Marui,  E., and Ema,  S., 1986, “Whirling Vibration in Drilling. Part 1: Cause of Vibration and Role of Chisel Edge,” ASME J. Ind., 108, pp. 157–162.
Fujii,  H., Marui,  E., and Ema,  S., 1986, “Whirling Vibration in Drilling. part 2: Influence of Drill Geometries, Particularly of the Drill Flank, on the Initiation of Vibration,” ASME J. Ind., 108, pp. 163–168.
Fujii,  H., Marui,  E., and Ema,  S., 1988, “Whirling Vibration in Drilling. Part 3: Vibration Analysis in Drilling Workpiece With a Pilot Hole,” ASME J. Ind., 110, pp. 315–321.
Lin, C., Jalisi, M. N., and Ehmann, K. F., 1991, “Modeling and Experimental Analysis of Margin Forces in Micro-Drilling,” ASME Manufacturing Processes and Materials Challenges in Microelectronic Packaging, AMD-Vol. 131/EEP-Vol. 1, pp. 25–33.
Chen,  W. R., and Keer,  L. M., 1993, “Transverse Vibrations of a Rotating Twisted Timoshenko Beam Under Axial Loading,” ASME J. Vibr. Acoust., 115, pp. 285–294.
Tekinalp,  O., and Ulsoy,  A. G., 1989, “Modeling and Finite Element Analysis of Drill Bit Vibrations,” ASME J. Vibr. Acoust., Stress, Reliab. Des. 111, pp. 148–155.
Rincon,  D. M., and Ulsoy,  A. G., 1995, “Complex Geometry, Rotary Inertia and Gyroscopic Effects on Drill Vibrations,” J. Sound Vib., 188, pp. 701–715.
Lee,  C. W., Katz,  R., Ulsoy,  A. G., and Scott,  R. A., 1988, “Modal Analysis of Distributed Parameter Rotating Shaft,” J. Sound Vib., 122, pp. 119–130.
Rincon,  D. M., and Ulsoy,  A. G., 1995, “Complex Geometry, Rotary Inertia, and Gyroscopic Moment Effects on Drill Vibrations,” J. Sound Vib., 188(5), pp. 701–715.
Ulsoy,  A. G., and Tekinalp,  O., 1984, “Dynamic Modeling of Transverse Drill Bit Vibrations,” CIRP Ann., 33(1), pp. 253–258.
Choi,  S. H., Pierre,  C., and Ulsoy,  A. G., 1992, “Consistent Modeling of Rotating Timoshenko Shafts Subject to Axial Loads,” ASME J. Vibr. Acoust., 114, pp. 249–259.
Lee,  S. J., Eman,  K. F., and Wu,  S. M., 1987, “An Analysis of the Drill Wandering Motion,” ASME J. Eng. Ind., 109, pp. 297–305.
Chiou, R. Y., and Wu, K., 1998, “Analysis of the Runout Effecton Hole Quality in Drilling,” Proceedings of the ASME Manufacturing Science and Engineering Division, pp. 651–658.
Surendran, V., 1998, “A Study of Hole Quality in Drilling,” Master’s thesis, University of Illinois at Urbana-Champaign, Urbana-Illinois.
Meirovitch, L., 1997, Principles and Techniques of Vibrations, Prentice-Hall, Inc., Upper Saddle River, New Jersey 07458.

Figures

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Alignment errors associated with the location of a drill in the spindle
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The effect of locating angle on the chip load
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Determination of the chip thickness along the cutting edges
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Methodology used for measuring the alignment errors
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Experimental setup to measure the vibrations of the drill and the forces during drilling
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Vibrations of the drill: Test 1
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x-component of the radial force: Test 1
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Vibrations of the drill: Test 1
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Variation of the net runout with varying ϕ
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Effects of α and ϕ on (a) P-to-V radial forces and (b) drill vibrations

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