Finite element simulation of drilling operation and theoretical analysis of drill stresses with the deform-3D

Yildiz A., KURT A. , YAĞMUR S.

SIMULATION MODELLING PRACTICE AND THEORY, cilt.104, 2020 (SCI İndekslerine Giren Dergi) identifier identifier


In this study, it was aimed to improve the cutting performance of the cutting tool (drill) used in drilling which is of great importance in the industry. The study includes experimental determination of thrust force and torque occurred during drilling, and analysis of the effects of these cutting loads on cutting tool with the Deform-3D program based on finite element method (FEM). For this purpose, various drilling experiments with uncoated and TiAlN/TiN coated solid carbide drills were conducted on full solid and pre-drilled AISI 1050 samples using different cutting parameters (cutting speeds of 60, 75, 90, 108 m/min and feed rates of 0.15, 0.20, 0.25 mm/rev). Kistler 9272 type dynamometer was used to measure the thrust force and torque occurring during the drilling experiments. The stress effects of the experimentally measured thrust force and torque on the drill were analysed. In order to improve the performance of the drill, the drilling operation was simulated and the relationships between cutting parameters and stresses were investigated using the Deform3D program. The results obtained from the study will provide significant contributions to improving the cutting performance of the drill and to the selection of optimum cutting parameters. The stress analysis approach applied in the study can also be applied to other metal cutting operations such as turning and milling, and evaluations can be made regarding the design of cutting tools.