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TECHNICAL PAPERS

Dynamics of Initial Penetration in Drilling: Part 1—Mechanistic Model for Dynamic Forces

[+] Author and Article Information
Yongping Gong, Cheng Lin, Kornel F. Ehmann

Department of Mechanical Engineering, Northwestern University, 2145 Sheridan Road, Evanston, IL 60208-3111

J. Manuf. Sci. Eng 127(2), 280-288 (Apr 25, 2005) (9 pages) doi:10.1115/1.1852569 History: Received January 07, 2002; Revised January 15, 2004; Online April 25, 2005
Copyright © 2005 by ASME
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References

Oxford,  C. J., 1955, “On the Drilling of Metals I-Basic Mechanics of the Process,” ASME Trans.,77, pp. 103–114.
Shaw,  M. C., and Oxford,  C. J., 1957, “On the Drilling of Metals, II: The Torque and Thrust in Drilling,” ASME Trans.,79, pp. 139–148.
Williams,  R. J., 1974, “A Study of the Drilling Process,” J. Eng. Ind., 96, pp. 1207–1215.
Armarego,  E. J. A., and Cheng,  C. Y., 1972, “Drilling With Flat Rake Face and Conventional Twist Drill-I. Theoretical Investigation,” Int. J. Mach. Tool Des. Res.,12, pp. 17–35.
Watson,  A. R., 1985, “Geometry of Drill Element,” J. Machine Tool Des. Res.,25(3), pp. 209–227.
Kaminski,  J., and Crafoord,  R., 1994, “Positional Accuracy of Holes When Drilling in Inclined Workpiece Surfaces, Part I-Experimental Results,” Proc. Inst. Mech. Eng.,208, pp. 129–139.
Kaminski,  J., and Crafoord,  R., 1994, “Positional Accuracy of Holes When Drilling in Inclined Workpiece Surfaces, Part II-Mathematical Force Model,” Proc. Inst. Mech. Eng.,208, pp. 141–152.
Chandrasekharan,  V., Kapoor,  S. G., and Devor,  R. E., 1995, “A Mechanistic Approach to Predict the Cutting Force in Drilling: With Application to Fiber-Reinforced Composite Materials,” J. Eng. Ind., 117, pp. 559–570.
Lin, C., Jalisi, M. N., and Ehmann, K. F., 1994, “Experimental Analysis of Initial Penetration in Drilling,” Materials Issues in Machining-II, edited by Stephenson, D. A. and Stevenson, R., pp. 383–408, TMS, Warrendale.
Gu,  F., Kapoor,  S. G., DeVor,  R. E., and Bandyopadhyay,  P., 1992, “A Cutting Force Model for Force Milling With a Step Cutter,” Trans. NAMRI/SME, 20, 1992, pp. 361–367.
Oxley,  P. L. B., 1963, “Rate of Strain Effect in Metal Cutting,” ASME J. Eng. Ind., 85, pp. 339–345.
Stephenson, D. A., and Bandyopadhyay, P., 1995, “Process Independent Force Characterization for Metal Cutting Simulation,” GM Non-classified Publication, No. R&D-8301.
Usui,  E., Hirota,  A., and Masuko,  M., 1978, “Analytical Prediction of Three Dimensional Cutting Process, Part I: Basic Cutting Model and Energy Approach,” J. Eng. Ind., 100, pp. 222–228.
Mauch, C. A., and Lauderbaugh, L. K., 1990, “Modeling the Drilling Process—An Analytical Model to Predict Thrust Force and Torque,” ASME Winter Meeting, Dallas, pp. 59–65.
Kachanov, L. M., 1971, Foundation of the Theory of Plasticity, North-Holland, Amsterdam, pp. 245–251.
Gong, Y. P., 2001, “Modeling and Simulation of Micro-Drilling Dynamics,” Ph.D thesis, Northwestern University, Evanston, Illinois.
Chandrasekharan,  V., Kapoor,  S. G., and Devor,  R. E., 1997, “A Calibration Procedure for Fundamental Oblique-Cutting Model Coefficients Based on a Three Dimensional Mechanistic Drilling Force Model,” Trans. NAMRI/SME,25, 1997, pp. 255–260.

Figures

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The dynamic drilling process model
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Coordinate frame definitions
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Elemental model for the major cutting edges
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Chip thickness variations due to the drill’s transverse deflections
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Chip thickness variations due to the drill’s angular deflections
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Chip thickness variations due to relative height grinding error
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Chip thickness variations due to the cutting edge relative angular grinding error
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Chisel edge cutting on an inclined surface
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Dynamic cutting areas of the major cutting edges
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Forces acting on an element of the major cutting edge
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Deformation in the indentation zone

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