Technical Briefs

Mathematical Modeling of Cutting Forces in Microdrilling

[+] Author and Article Information
Kumar Sambhav

Indian Institute of Technology Kanpur,
Kanpur, Uttar Pradesh, 208016, India
e-mail: ksambhav@outlook.com

Puneet Tandon

Dean, Planning and Development
Professor, Mechanical Engineering Discipline
Professor & Coordinator, Design Discipline
PDPM Indian Institute of Information Technology,
Design & Manufacturing Jabalpur,
Jabalpur, 482 011, India
e-mail: ptandon@iiitdmj.ac.in

Shiv G. Kapoor

Grayce Wicall Gauthier Chair Mechanical
Science and Engineering
Director, Center for Machine Tools Systems Research
4416 Mechanical Engineering Laboratory,
University of Illinois at Urbana Champaign,
1206 West Green Street, MC-244,
Urbana, IL 61801
e-mail: sgkapoor@illinois.edu

Sanjay G. Dhande

Mechanical Engineering and Computer Science & Engineering,
Indian Institute of Technology Kanpur,
Kanpur, Uttar Pradesh, 208016, India
e-mail: sgd@iitk.ac.in; sgdhande1@gmail.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received March 13, 2011; final manuscript received October 10, 2012; published online January 7, 2013. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 135(1), 014501 (Jan 07, 2013) (8 pages) Paper No: MANU-12-1082; doi: 10.1115/1.4007955 History: Received March 13, 2011; Revised October 10, 2012

In drilling, the primary and secondary cutting lips of the drill shear the material while the central portion of the chisel edge indents the workpiece, making the cutting process complex to understand. As we go for microdrilling, it exhibits an added complexity to the cutting mechanism as the edge radius gets comparable to chip thickness at low feeds. The presented work models the forces by the primary cutting lip of a microdrill analytically using slip-line field that includes the changes in the effective rake angle and dead metal cap during cutting for cases of shearing as well as ploughing. To study the variation of forces experimentally, the primary cutting lip and chisel edge forces are separated out by drilling through pilot holes of diameter slightly above the drill-web thickness. Finally, the analytical and experimental results are compared and the model is calibrated.

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Fig. 1

Minimum chip thickness effect [18] (a)tc < tce,(b)tce ≤ tc < tcmin,(c)tc≥tcmin

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Fig. 2

Effective rake angle concept [19]

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Fig. 3

Dead cap formation below the cutting edge [20]

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Fig. 4

Formation of a prow [4,5]

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Fig. 5

Dead metal cap and raised prow formation in microcutting [16]

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Fig. 6

Primary cutting lips, chisel edge, the indentation zone, and the secondary cutting lips [21]

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Fig. 7

Cutting lip vector

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Fig. 8

Velocity vector at the cutting edge

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Fig. 9

Orthogonal cutting forces resolved along actual cutting and lateral directions

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Fig. 10

Slip line field and hodograph for the case of chip formation [5]

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Fig. 11

Slip line field and hodograph for the case of ploughing without chip formation [5]

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Fig. 12

(a) Experimental setup on Microlution 310 S and (b) force sensor at the load cell

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Fig. 13

SEM images of microdrill of diameter 508 μm

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Fig. 14

A typical thrust profile from microdrilling through pilot holes

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Fig. 15

Comparison of experimental and analytical data



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