Skip to main content
SpringerLink
Log in

Experimental studies and FEM simulation of helical-shaped deep hole twist drills

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

This study investigates the chip formation in drilling of AISl 316L stainless steel using TiAIN coated helical-shaped deep hole twist drills. The aim of this research is to determine suitable cutting parameters with a focus on favourable chip formation, to achieve a better process stability. The experimental investigations were conducted with varying cutting speed, feed rate and cooling lubricant pressure, in stages that were based on the recommendations of the tool manufacturer. In addition to the experimental tests, the mechanical loads and chip formation were simulated with the aim of providing a basis for the simulative development of the tool shape and the cutting parameters. With mathematical methods, a geometrical kinematic imprint, in accordance to the axial feed force of the helical-shaped deep hole twist drill, was implemented into the three-dimensional workpiece model. Based on the experimental results, which show that the chip shape has a great dependence on the feed rate, which in turn strongly affects the feed force and the drilling torque suitable cutting parameters were chosen for the simulation. The simulation results were validated with the experimental data and show a good agreement.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

Abbreviations

A:

Yield stress, N/mm2

AG :

Elongation, %

B :

Strain hardening

C :

Strain hardening coefficient

c p,w :

Specific heat, J/(kg K)

D :

Bore hole diameter, mm

d :

Tool diameter, mm

F t :

Feed force, N

f :

Feed rate, mm

h :

Heat transfer coefficient, W/m2 K

k w :

Thermal conductivity, W/(m K)

l t :

Drilling depth, mm

l tmax :

Maximum drilling depth, mm

l sim :

Simulation length, mm

l :

Length, mm

M t :

Torque, Nm

m :

Exponent for softening

n :

Rotation speed, min−1

n max :

Maximum rotation speed, min−1

p:

Coolant pressure, bar

p max :

Maximum coolant pressure, bar

p min :

Minimum coolant pressure, bar

l/d :

Length-to-diameter ratio

R :

Drill radius, mm

R m,RT :

Ultimate tensile strength, MPa

R p0.2 :

Yield strength, MPa

t :

Time, s

T :

Temperature, K

T r :

Reference temperature, K

T m :

Melting temperature, K

v :

Viscosity, mm2/sec

\(\dot {v}\) :

Volume flow, L/min

v c :

Cutting speed, m/min

v f :

Feed velocity, mm/s

v fmax :

Maximum feed rate, mm min−1

Z:

Reduction of area, %

\(\alpha \) :

Cutting lip angle, degree

λ :

Thermal conductivity, W/m K

\(\varepsilon \) :

Plastic strain, -

\(\dot {\varepsilon }\) :

Strain rate, 1/s

\({\dot {\varepsilon }_0}\) :

Reference strain rate, 1/s

\(\sigma \) :

Equivalent stress, N/mm2

\({\varvec{\upvarrho}_w}\) :

Density, kg/m3

max :

Maximum

min :

Minimum

RT :

Room temperature

BHN:

Hardness brinell

CAD:

Computer-aided design

3D:

Three-dimensional

FEM:

Finite element method

STL:

Standard tessellation language

TiAlN:

Titanium aluminum nitride

References

  1. Biermann D, Iovkov I, Blum H, Rademacher A, Taebi K, Suttmeier FT, Klein N (2012) Thermal aspects in deep hole drilling of aluminium cast alloy using twist drills and MQL. Proc CIRP 3:245–250. https://doi.org/10.1016/j.procir.2012.07.043

    Article  Google Scholar 

  2. Klocke F, Keitzel G, Veselovac D (2014) Innovative sensor concept for chip transport monitoring of gun drilling processes. Proc CIRP 14:460–465. https://doi.org/10.1016/j.procir.2014.03.096

    Article  Google Scholar 

  3. Schnabel D, Oezkaya E, Biermann D, Eberhard P (2017) Modeling the motion of the cooling lubricant in drilling processesusing the finite volume and the smoothed particle hydrodynamics methods. Comput Method Appl Mech Eng. https://doi.org/10.1016/j.cma.2017.09.015

    Google Scholar 

  4. Fallenstein F, Aurich JC (2014) CFD based Investigation on internal cooling of twist drills. Proc CIRP 14:293–298. https://doi.org/10.1016/j.procir.2014.03.112

    Article  Google Scholar 

  5. Biermann D, Blum H, Frohne J, Iovkov I, Rademacher A, Rosin K (2015) Simulation of MQL deep hole drilling for predicting thermally induced workpiece deformations. Proc CIRP 31:148–153. https://doi.org/10.1016/j.procir.2015.03.038

    Article  Google Scholar 

  6. Heinemann R, Hinduja S, Barrow G, Petuelli G (2006) Effect of MQL on the tool life of small twist drills in deep-hole drilling. Int J Mach Tool Manuf 46:1–6. https://doi.org/10.1016/j.ijmachtools.2005.04.003

    Article  Google Scholar 

  7. Hossain S, Truman CE, Smith DJ (2012) Finite element validation of the deep hole drilling method for measuring residual stresses. Int J Pres Ves Pip 93–94:29–4. https://doi.org/10.1016/j.ijpvp.2012.02.003

    Article  Google Scholar 

  8. Biermann D, Iovkov I (2015) Investigations on the thermal workpiece distortion in MQL deep hole drilling of an aluminium cast alloy. CIRP Ann Manuf Technol 64:85–88. https://doi.org/10.1016/j.cirp.2015.04.072

    Article  Google Scholar 

  9. Biermann D, Kersting M, Kessler N (2009) Process adapted structure optimization of deep hole drilling tools. CIRP Ann Manuf Technol 58:89–92. https://doi.org/10.1016/j.cirp.2009.03.102

    Article  Google Scholar 

  10. Kara F, Aslantaş K, Çiçek A (2016) Prediction of cutting temperature in orthogonal machining of AISI 316L using artificial neural network. Appl Soft Comput 38:64–74. https://doi.org/10.1016/j.asoc.2015.09.034

    Article  Google Scholar 

  11. Maranhão C, Paulo Davim J (2010) Finite element modelling of machining of AISI 316 steel. Simul Model Prac Theory 18:139–156. https://doi.org/10.1016/j.simpat.2009.10.001

    Article  Google Scholar 

  12. Uhlmann E, Richarz S (2016) Twisted deep hole drilling tools for hard machining. J Manuf Process 24:225–230. https://doi.org/10.1016/j.jmapro.2016.09.013

    Article  Google Scholar 

  13. Ucun İ, Aslantas K, Özkaya E, Cicek A (2017) 3D numerical modelling of micro-milling process of Ti6Al4V alloy and experimental validation. Adv Mater Res Switz 3:250–260. https://doi.org/10.1080/2374068X.2016.1247343

    Google Scholar 

  14. Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21:31–48. https://doi.org/10.1016/0013-7944(85)90052-9

    Article  Google Scholar 

  15. Biermann D, Kirschner M, Eberhardt D (2014) A novel method for chip formation analyses in deep hole drilling with small diameters. J Therm Stress 8:491–497. https://doi.org/10.1080/01495730802637134

    Google Scholar 

  16. Miguélez MH, Zaera R, Molinari A (2009) Residual Stresses in orthogonal cutting of metals. J Therm Stress 32:269–289. https://doi.org/10.1080/01495730802637134

    Article  Google Scholar 

  17. Chandrasekaran H, M’Saoubi R, Chazal H (2005) Modelling of material flow stress in chip formation process from orthogonal milling and split Hopkinson bar tests. Mach Sci Technol 9:131–145. https://doi.org/10.1081/MST-200051380

    Article  Google Scholar 

  18. Umbrello D, M’Saoubi R, Outeiro JC (2007) The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel. Int J Mach Tool Manuf 47:462–470. https://doi.org/10.1016/j.ijmachtools.2006.06.006

    Article  Google Scholar 

Download references

Acknowledgements

The authors gratefully acknowledge funding from the German Research Foundation (DFG) for the research Project (BI 498/80).

Author information

Authors and Affiliations

  1. Institute of Machining Technology, 44227, Dortmund, Germany

    Ekrem Oezkaya, Sebastian Michel & Dirk Biermann

Authors
  1. Ekrem Oezkaya
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Sebastian Michel
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Dirk Biermann
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Ekrem Oezkaya.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Oezkaya, E., Michel, S. & Biermann, D. Experimental studies and FEM simulation of helical-shaped deep hole twist drills. Prod. Eng. Res. Devel. 12, 11–23 (2018). https://doi.org/10.1007/s11740-017-0779-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-017-0779-7

Keywords

Search

Navigation