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HomeAdvanced Materials ResearchModelling of Machining Operations3D Modelling and Simulation of Gun Drilling
Abstract:
The main objective of this paper is the development and validation of a three dimensional thermomechanically coupled finite element model for gun drilling AISI 4150 quenched and tempered steel. The Lagrangian formulation proposed in the FE code DEFORM 3DTM and the constitutive Johnson-Cook material model were utilized to simulate the chip formation and to predict the cutting reaction forces as well as the temperature in gun drilling process using carbide gun drills with two different diameters. During gun drilling simulation, modified gun drill cutting edge rounding and friction law are performed to investigate the effect of tool wear and lubrication on feed force and torque respectively. Experimental gun drilling tests were carried out in steel AISI 4150 for the validation of the developed 3D FE model. The developed and validated 3D FE model can be used for optimizing the cutting process in gun drilling (good surface finish and straightness) taking into account the complex gun drill geometry, cutting conditions, heat transfer and the thermo-mechanical behaviour of the workpiece material.
Fritz Klocke, Mustapha Abouridouane, Klaus Gerschwiler, Dieter Lung
Deform 3DTM, FE Modeling, Gun Drilling, Johnson-Cook, Steel AISI 4150
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Abstract: Drilling is one of the most complex machining processes. The 3D coupled thermo-mechanical model was developed based on Third Wave Systems AdvantEdge to study the drilling process. The workpiece was set as elastic-plastic model, which considering strains hardening, heat generation of friction in tool-chip interface and shearing deformation. Adaptive meshing technology was used, the mesh of work region refined. Contrast tests were conducted to study the chip, drilling forces and drilling temperature in drilling 45 steel and TI6AL4V. Results indicated that the results of simulation were according to experimental results; the torque of drilling TI6AL4V was less than that of drilling 45 steel, but the drilling temperature was higher than that of drilling 45 steel. Thus, finite element simulation is also an important tool to study the drilling process.
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Abstract: Drilling is a widely used machining process for various components pertaining to industries such as aerospace, automobile etc. Ti6Al4V is very often used for high stressed components like aircraft structure because of its excellent strength to weight ratio. Tool geometry plays a vital role in effective drilling. It is very difficult to develop a modified geometry in order to achieve better hole quality and improved tool life and validating its outcome experimentally is very expensive. The current paper presents the concept of drilling simulation process using commercial finite element software, Abaqus/Explicit. Five major drill bit geometry such as point angle, helix angle, clearance diameter, and web thickness were varied The proposed simulation model for drilling process was based on Eulierian formulation with explicit interaction. The results of simulation were compared with that of experimental drilling. The simulated result has a good correlation with the experimental result. The change in reference point to chisel tip in the simulation yielded better results as compared to when the reference point is taken at top surface of the tool.
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