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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

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.
Maxey,  R., 1999, “High Performance Twist Drills in Perspective,” Modern Machine Shop, 72 (1), pp. 72–79.
Spur,  G., and Masuha,  J. R., 1981, “Drilling With Twist Drills of Different Cross Section Profiles,” CIRP Ann., 30, pp. 31–35.
Chen,  Y. R., and Ni,  J., 1999, “Analysis and Optimization of Drill Cross-Sectional Geometry,” Transactions of NAMRI/SME, 27, pp. 99–104.
Thornley,  R. H., Wahab,  A. B. I. E., and Maiden,  J. D., 1987, “Some Aspects of Twist Drill Design,” Int. J. Mach. Tools Manuf., 27, pp. 383–397.
Agapiou,  J. S., 1993, “Design Characteristics of New Types of Drill and Evaluation of Their Performance Drilling Cast Iron-II. Drills With Three Major Cutting Edges,” Int. J. Mach. Tools Manuf., 33, pp. 343–365.
Mellinger,  J. C., Ozdoganlar,  O. B., DeVor,  R. E., and Kapoor,  S. G., 2002, “Modeling Chip-Evacuation Forces and Prediction of Clip-Clogging in Drilling,” ASME J. Manuf. Sci. Eng., 124, pp. 605–614.
Tadmor, Z., and Gogos, C. G., 1979, Principles of Polymer Processing, John Wiley and Sons, Inc.
Chen, Y., 1999, “Drilling Process Modeling for New Drilling Process Development,” PhD thesis, University of Michigan.
Munem, M. A., and Foulis, D. J., 1984, Calculus, Worth Publishers.
Colley, S. J., 1998, Vector Calculus, Prentice Hall.
Roy, R., and Craig, J., 1996, Mechanics of Materials, John Wiley & Sons, Inc.
Ludema, K. C., 1996, Friction, Wear, Lubrication: A Textbook in Tribology, CRC Press, Inc.
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.

Figures

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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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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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Flute surface boundary curve length Sf along the flute length

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