PRESENTED BY

VINOOP TK M110122ME
MANUFACTURING TECNOLOGY

CONTENTS
1 INTRODUCTION 2 MODEL DEVELOPMENT
2.1 MODEL OVERVIEW 2.2 FORCES ON THE RESTRICTED-CONTACT DRILLS 2.3 FORCES ON THE GROVED DRILLS 2.4 DETERMINATION OF TOOL CHIP NATURAL STICKING LENGTH

3 EXPERIMENTAL WORK
3.1 FORCE MODEL CALIBERATION 3.2 VALIDATION EXPERIMENT FOR STICKING LENGTH MODEL 3.3 FORCE MODEL VALIDATION

4 DISCUSSION OF RESULTS 5 USE OF THE FORCE MODEL FOR OPTIMUM GROOVE DESIGN 6 CONCLUSIONS

1 INTRODUCTION
CHIPS PRODUCED IN DRILLING MUST FLOW OUT OF THE HOLE THROUGH NARROW HELICAL FLUTES ON THE DRILL IF THE CHIPS ARE NOT REMOVED WELL IT WILL CAUSE INCRESED FRICTION BETWEEN TOOL & CHIPS LONG CONTINUOUS CHIPS CAN CAUSE SEVERE CHIP MANAGEMENT PROBLEMS CHIP CLOGGING WILL CAUSE PREMATURE FAILURE OF TOOL CHIP BREAKING IMPROVES BETTER CHIP EVACUTION & HOLE QUALITY VIBERATION-ASSISTED DRILLING CAN BREAKE CHIPS BUT IT IS EXPENSIVE

2 MODEL DEVELOPMENT
2.1 MODEL OVERVIEW

CHIP SLIDING AREA

Grove specification

C groove trailing edge, Wg is the width of groove, Hg is the . depth of groove, Rg is the groove radius, Bg is the groove back-wall height, z is the groove entry angle, and Lc is the land length.

2.2 FORCES ON THE RESTRICTED-CONTACT DRILLS

, are specific cutting energies

is elemental chip load

(1)

(2) For ordinary rake faced drills

(3)

(4)

 , and are obtained by solving the above equation

2.3 FORCES ON THE GROVED DRILLS

(5)

(6)

(7)

(8)

Relationship between angle made by the tangent to the chip at groove back-wall and groove geometry

= +

2 tan1

(9)

(10)

(11)

(12)

(13)

2.4 DETERMINATION OF TOOL CHIP NATURAL STICKING LENGTH

3 EXPERIMENTAL WORK
TWO TYPES OF VALIDATION EXPERIMENTIS CONDUCTED
CALIBERATION EXPERIMENTS FOR SPECIFIC CUTTING ENERGIES TOOL CHIP NATURAL STICKING LENGTH MODEL FORCE MODEL
Experiments were conducted on an OKUMA MC-4VAE vertical machining center. A Kistler Model 9273 dynamometer was used for collecting the torque and thrust forces.

3.1 FORCE MODEL CALIBERATION

Calibration experiments were performed at four different speed and feed conditions and torque and thrust data were collected. (f=0.14mm/rev , s=800rpm),(f=0.14mm/rev , s=1600rpm) (f=0.24mm/rev , s=800rpm),(f=0.24mm/rev , s=1600rpm)

3.2 VALIDATION EXPERIMENT FOR STICKING LENGTH MODEL

Digital photograph showing three regions in the rake face

L=2Rsin

2
Relationship between land length and chord length

Comparison of model-predicted and experimental sticking length values along cutting edge

3.3 FORCE MODEL VALIDATION

The angle of the groove from the cutting edge and the width of the groove are the two groove geometric parameters that affect the forces during drill. Groove geometries used for the validation experiments

Using the groove parameters , calibration and model equations developed in the previous section , the cutting thrust and torque values were predicted for the validation process conditions.

4 DISCUSSION OF RESULTS
Predicted and experimental steady-state forces

Average prediction error was 10.7% It is also seen that the thrust decreases with the decrease in angle of groove and increase in width of the groove. In most cases it is also found that the torque decreases with decrease in both the angle and width of groove

5 USE OF THE FORCE MODEL FOR OPTIMUM GROOVE DESIGN

Simulated test conditions and associated force

responses

Thrust=818.1 + 39.81 + 74.32 + 125.33 + 16.54 + 37.31 2

= 703.5 34.11 + 107.12 + 59.53 + 24.42 3 21.61 3 4

(x1 is the speed, x2 is the feed, x3 is the groove angle, and x4 is the groove width)

6 CONCLUSIONS
1. A mechanistic model for the thrust and torque due to the cutting edges of the drill is developed in which the effect of the groove placed on the rake face is incorporated. 2. Calibration and validation experiments were conducted with low-carbon steel work-pieces and high-speed steel drills. The predicted forces were found to be in good agreement with the experimental data with an average prediction error of about 10.7%. 3. It was observed that the thrust decreases with the decrease in angle of the groove and increase in width of the groove. Torque decreases with decrease in both the angle and width of the groove.

REFERANCES
Sahu, S. K., DeVor, R. E., Kapoor, S. G., and Ozdoganlar, O. B., 2003, Effect of Groove-Type Chip-Breakers on Twist Drill Performance, Int. J. Mach. Tools Manuf., 43, pp. 617627. Parakkal, G., Zhu, R., Kapoor, S. G., and DeVor, R. E., 2002, Modeling ofTurning Process Cutting Forces for Grooved Tools, Int. J. Mach. Tools Manuf., 42, pp. 179191. Fang, N., and Jawahir, I. S., 2002, An Analytical Predictive Model and Experimental Validation for Machining With Grooved Tools Incorporating the Effects of Strains, Strain-Rates, and Temperatures, CIRP Ann., 51, pp. 8. Jeff A. Degenhardt, DeVor,R. E., Kapoor,S. G. , Generalized groove-type chip breaker effects on drilling for different drill diameters and flute shapes, Int. J. Mach. Tools Manuf., 45 (2005) 15881597.

QUESTIONS

THANKS