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TECHNICAL PAPERS

Modeling Chip-Evacuation Forces in Drilling for Various Flute Geometries

[+] 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 125(3), 405-415 (Jul 23, 2003) (11 pages) doi:10.1115/1.1578671 History: Received September 01, 2001; Revised November 01, 2002; Online July 23, 2003
Copyright © 2003 by ASME
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References

Figures

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Chips when drilling cast aluminum 356-T6
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Typical plot of the torque varying with depth
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Typical plot of the thrust varying with depth
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Typical drill engaged in the workpiece showing the location of the differential chip section
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Differential chip section with the associated forces
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Cross-section view (AA) of Fig. 4 for a standard twist drill in the chip section coordinate system
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Lateral section used for the force balance to obtain the lateral pressure distribution
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Parabolic drill cross-section in the chip section coordinate system
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Measured data of the transverse cross-section of the parabolic drill
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Chip section boundaries and the unit vectors for the parabolic drill
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Predicted and experimental chip-evacuation torque for validation test 4
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Predicted and experimental chip-evacuation thrust for validation test 4
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Experimental and predicted critical depths for validation test 4 for the standard drill
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Experimental and predicted critical depths for validation test 9 for the parabolic drill
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Chip-evacuation torque for validation test 5 using predicted and average values of μf and μw
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Chip-evacuation thrust for validation test 5 using predicted and average values of μf and μw
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Effective flute cross-sectional area Ao along the flute length
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Flute surface boundary curve length Sf along the flute length

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