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TECHNICAL PAPERS

Modeling of Forces for Drills With Chip-Breaking Grooves

[+] Author and Article Information
Sushanta K. Sahu

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 126(3), 555-564 (Sep 07, 2004) (10 pages) doi:10.1115/1.1763183 History: Received January 01, 2003; Revised December 01, 2003; Online September 07, 2004
Copyright © 2004 by ASME
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References

Litvinov,  L. P., 1990, “Vibration-Assisted Drilling of Deep Holes,” Soviet Engineering Research,10(5), pp. 5–8.
Nakayama,  K., and Ogawa,  M., 1985, “Effect of Chip Splitting Nicks in Drilling,” CIRP Ann., 34(1), pp. 101–104.
Sahu,  S. K., DeVor,  R. E., Kapoor,  S. G., and Ozdoganlar,  O. B., 2003, “Effect of Groove-Type Chip-Breakers on Twist Drill Performance,” Int. J. Mach. Tools Manuf., 43, pp. 617–627.
Sahu, S. K., 2003, “Modeling and Analysis of Groove-Type Chip-Breakers on Twist Drills,” MS thesis, University of Illinois, Urbana Champaign.
Chandrasekharan,  V., DeVor,  R. E., and Kapoor,  S. G., 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.
Shi,  T., and Ramalingam,  S., 1993, “Modeling Chip Formation With Grooved Tools,” Int. J. Mech. Sci., 35, pp. 741–756.
Fang,  N., and Jawahir,  I. S., 2002, “An Analytical Predictive Model and Experimental Validation for Machining With Grooved Tools Incorporating the Effects of Strains, Strain-Rates, and Temperatures,” CIRP Ann., 51, pp. 83–86.
Athavale,  S. M., and Strenkowski,  J. S., 1997, “A Partially Constrained Eulerian Orthogonal Cutting Model for Chip Control Tools,” ASME J. Manuf. Sci. Eng., 119, pp. 681–688.
Zhu,  R., Kapoor,  S. G., DeVor,  R. E., and Athavale,  S. M., 1999, “Mechanistic Force Models for Chip Control Tools,” ASME J. Manuf. Sci. Eng., 121(3), pp. 408–416.
Parakkal,  G., Zhu,  R., Kapoor,  S. G., and DeVor,  R. E., 2002, “Modeling of Turning Process Cutting Forces for Grooved Tools,” Int. J. Mach. Tools Manuf., 42, pp. 179–191.
Rubenstein,  C., Venuvinod,  P. K., and Lau,  W. S., 1986, “Analysis of Oblique Cutting With Controlled Contact Tools,” CIRP Ann., 35(1), pp. 51–54.
Chao,  B. T., and Trigger,  K. J., 1959, “Controlled Contact Cutting Tools,” Trans. ASME, 81, pp. 139–151.
Sata, T., 1963, “Recent Development Concerning Cutting Mechanics,” Proceedings of International Production Engineering Research Conference, Pittsburgh, PA, pp. 18–25.
Chandrasekharan,  V., DeVor,  R. E., and Kapoor,  S. G., 1997, “A Calibration Procedure for Fundamental Oblique-Cutting Model Coefficients Based on a Three-Dimensional Mechanistic Drilling Force Model,” Transactions of NAMRI/SME,XXV, pp. 255–260.
Altintas,  Y., and Shamoto,  E., 1999, “Prediction of Shear Angle in Oblique Cutting With Maximum Shear Stress and Minimum Energy Principles,” ASME J. Manuf. Sci. Eng., 121, pp. 399–407.
Nedess,  C., and Hintze,  W., 1989, “Characteristic Parameters of Chip Control in Turning Operations With Indexable Inserts and Three-Dimensionally Shaped Chip Formers,” CIRP Ann., 38(1), pp. 74–79.
Worthington,  B., and Rahman,  M. H., 1979, “Predicting Breaking With Groove Type Breakers,” Int. J. Mach. Tool Des. Res., 19(3), pp. 121–132.
Boothroyd,  G., and Bailey,  A. J., 1966, “Effects of Strain Rate and Temperature in Orthogonal Metal Cutting,” J. Mech. Eng. Sci., 8, pp. 264–269.
DeVor, R. E., Chang, T., and Sutherland, J. W., 1992, Statistical Quality Design and Control—Contemporary Concepts and Methods, Prentice-Hall, New Jersey, pp. 542–573.

Figures

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Drill coordinate systems
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Chip-Breaker groove location
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Forces acting on an oblique cutting element of a restricted contact drill
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Forces acting on an oblique cutting element of a grooved drill
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Relationship between angle made by the tangent to the chip at groove back-wall and groove geometry
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Lateral, cutting, and vertical forces
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Summary of modeling methodology
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Speed and feed conditions for model calibration and validation
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Digital photograph showing three regions in the rake face
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Relationship between land length and chord length
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Contours for thrust (N) at 1300 RPM, 0.2 mm/rev
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Contours for torque (N-cm) at 1300 RPM, 0.2 mm/rev
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Difference in chip size between grooved and ungrooved drills
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Torque contours (N-cm) at speed=1000 RPM, feed=0.16 mm/rev
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Torque contours (N-cm) at speed=1000 RPM, feed=0.22 mm/rev
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Torque contours (N-cm) at speed=1400 RPM, feed=0.16 mm/rev
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Torque contours (N-cm) at speed=1400 RPM, feed=0.22 mm/rev

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