Research Papers

Force Modeling for Generic Profile of Drills

[+] Author and Article Information
Kumar Sambhav

School of Civil and Mechanical Engineering,
Galgotias University,
Greater Noida 201306, India
e-mail: ksambhav@outlook.com

Puneet Tandon

Jabalpur, Madhya Pradesh 482005, India
e-mail: ptandon@iiitdmj.ac.in

Sanjay G. Dhande

Indian Institute of Technology Kanpur,
Kanpur, Uttar Pradesh 208016, India
e-mail: sgd@iitk.ac.in

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 25, 2013; final manuscript received May 1, 2014; published online June 2, 2014. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 136(4), 041019 (Jun 02, 2014) (9 pages) Paper No: MANU-13-1183; doi: 10.1115/1.4027595 History: Received April 25, 2013; Revised May 01, 2014

The paper presents a methodology to model the cutting forces by twist drills with generic point geometry. A generic definition of point geometry implies that the cutting lips and the relief surfaces can have arbitrary shapes. Such geometry is easily modeled using Non Uniform Rational B-Spline (NURBS) surface patches which give sufficient freedom to the tool designer to alter the tool geometry. The drill point has three cutting zones: primary cutting lips, secondary cutting lips, and the indentation zone at the center of chisel edge. At the indentation zone, the drill extrudes the workpiece, while at the cutting lips, shearing takes place. At primary cutting lip, the cutting is oblique while at secondary cutting lip, it is predominantly orthogonal. Starting from a computer-aided geometric design of a fluted twist drill with arbitrary point profile, the cutting forces have been modeled separately for all the three cutting zones. The mechanistic method has been employed wherever applicable to have a good correlation between the analytical and the experimental results. The force model has been calibrated and validated for conical drills. Then the model has been evaluated for a drill ground with curved relief surfaces. The theoretical and experimental results are found out to be in good conformity.

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Fig. 1

Half of the sectional geometry of the generic drill model [12]

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Fig. 2

Generatrix of grinding surface of drill as NURBS [12]

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Fig. 3

Primary cutting lip, secondary cutting lip, and indentation zone on drill point [12]

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Fig. 4

Thrust in drilling through a pilot hole

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Fig. 5

Torque in drilling through a pilot hole

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Fig. 6

World and local coordinate frames for primary lip

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Fig. 7

Velocity vector at the lip

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Fig. 8

Face and flank angles during indentation

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Fig. 9

Slip-line field for indentation by a smooth, plane, symmetric, and perfectly rigid wedge

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Fig. 10

(a) EMCO CNC Machining Center and (b) drilling in progress

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Fig. 11

Grinding wheel with arbitrarily curved grinding surface [12]

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Fig. 12

Drill of 12.5 mm diameter ground with curved grinding surface [12]

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Fig. 13

World and local coordinate frames for generic drill point




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