Research Papers

Workpiece Thermal Distortion in Minimum Quantity Lubrication Deep Hole Drilling—Finite Element Modeling and Experimental Validation

[+] Author and Article Information
Bruce L. Tai, Andrew J. Jessop, David A. Stephenson, Albert J. Shih

Department of Mechanical Engineering,  University of Michigan, Ann Arbor, MI 48109

J. Manuf. Sci. Eng 134(1), 011008 (Jan 12, 2012) (9 pages) doi:10.1115/1.4005432 History: Received April 26, 2011; Revised November 01, 2011; Published January 12, 2012; Online January 12, 2012

This paper presents the three dimensional (3-D) finite element analysis (FEA) to predict the workpiece thermal distortion in drilling multiple deep-holes under minimum quantity lubrication (MQL) condition. Heat sources on the drilling hole bottom surface (HBS) and hole wall surface (HWS) are first determined by the inverse heat transfer method. A 3-D heat carrier consisting of shell elements to carry the HWS heat flux and solid elements to carry the HBS heat flux has been developed to conduct the heat to the workpiece during the drilling simulation. A thermal–elastic coupled FEA was applied to calculate the workpiece thermal distortion based on the temperature distribution. The concept of the heat carrier was validated by comparing the temperature calculation with an existing 2-D advection model. The 3-D thermal distortion was validated experimentally on an aluminum workpiece with four deep-holes drilled sequentially. The measured distortion on the reference point was 61 μm, which matches within uncertainty the FEA predicted distortion of 51 μm.

Copyright © 2012 by American Society of Mechanical Engineers
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Figure 1

(a) 2-D axisymmetric advection FEA model and (b) the corresponding experimental setup for the inverse heat transfer method

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Figure 2

Schematics of the (a) 3-D heat carrier model and (b) 3-D advection model

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Figure 3

The 3-D heat carrier model (a) assembled heat carrier, (b) HWS heat carrier, and (c) HBS heat carrier

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Figure 4

Definition of axial thickness (lb ), the geometry (EFGH) of the 2-D axisymmetric HBS heat carrier, and convergent temperature distribution due to constant HBS heat flux

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Figure 5

Temperature distributions around HBS in (a) 2-D advection model and (b) 2-D HBS heat carrier with k = 60%, and (c) the comparison of temperature results in the regions highlighted in (a) and (b)

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Figure 6

The lb determined by index p ranging from 0.4 to 13.7 mm with k = 60%

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Figure 7

(a) Surface temperature at 24.8 s drilling time in 3-D heat carrier model and (b) temperature comparison between 3-D heat carrier model and 2-D advection model

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Figure 8

Setup I: Cylindrical workpiece with five thermocouples embedded along the depth for the inverse heat transfer method

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Figure 9

Setup II: (a) workpeice design for thermal distortion experiment and (b) the measurement of hole positions using dial indicator (unit: mm)

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Figure 10

Results of the inverse heat transfer method: (a) measured and FEA calculated temperatures at thermocouple positions and (b) temporal and spatial distribution of hw

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Figure 11

The 3-D FEA mesh of the workpiece for multihole drilling

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Figure 12

Workpiece temperature distribution at (a) the end of drilling hole #1, (b) 6.5 s after the end of drilling hole #1, and the end of drilling (c) hole #2, (d) hole #3, and (e) hole#4

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Figure 13

Measured and predicted surface temperatures at points A, B, and C

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Figure 14

Two viewpoints of workpiece temperature distribution in 22 s after the end of hole #4 drilling

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Figure 15

Simulated workpiece distortion in X-direction at the start of drilling the reference holes

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Figure 16

Step-removal approach in the heat carrier model




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