Numerical Model for Prediction of Cutting Forces in a Vibratory Drilling Process

Abstract

The drilling operation is considered by manufacturers as complex and difficult process (rapid wear of the cutting edge as well as problems of chip evacuation). Faced with these failures, manufacturers have shifted in recent years towards the drilling process assisted by forced vibrations. This method consist to add an axial oscillation with a low frequency to the classical feed movement of the drill so as to ensure good fragmentation and better chip evacuation. This paper presents a model for prediction of cutting forces during a drilling operation assisted by forced low-frequency vibration. The model allows understanding the interaction between the tool and the workpiece and identifying numerically the three-dimensional evolution of the cutting force components generated by the vibratory drilling operation. The effects of cutting parameters, tool parameters and those of forced vibrations on the cutting forces distributions will be discussed.

FE Study of the Chips Morphology when Drilling Process

“…[10] The force in the axial direction of the tool(Thrust direction, green curve) reaches its maximum at the beginning of the contact between the tool and the work-piece. The tool at the beginning of this contact pushes the material prior to beginning the cut then this force declines to reach values very close since the tool vibration influence it [11]. The disturbance of the force causes delamination mainly at the input level of the holes this increase the size of a hole.…”