3D finite element analysis of Al7075-T6 drilling with coated solid tooling

Angelos Markopoulos,Anastasios Tzotzis,G Mansour,D Tzetzis,Nikolaos Karkalos,P Kyratsis,Panagiotis Kyratsis

doi:10.1051/matecconf/202031801038

Angelos Markopoulos, Anastasios Tzotzis + Show 5 more

Open Access

https://doi.org/10.1051/matecconf/202031801038

Copy DOI

Abstract

Due to the fact that simulation of drilling was added in commercial finite element analysis (FEA) software only recently, 3D finite element modelling is an invaluable asset during related researches. The present study employs 3D FEA to model the drilling process of Al7075-T6 alloy with solid carbide tooling, investigates important phenomena that occur during drilling and finally compares the simulated results with experimental data. A number of simulations were performed with DEFORM3D™ software at different cutting conditions; cutting speed of 50m/min, 100m/min, 150m/min and feed of 0.15mm/rev, 0.20mm/rev, 0.25mm/rev. The proposed model takes into consideration certain aspects like damage initiation and evolution of the material, contact interface between the drill bit and the workpiece and standard boundary conditions. Eventually, the acquired numerical data for thrust force were compared to the experimental results for the same cutting conditions and parameters. To obtain the experimental data, a series of nine drilling tests were performed. Upon validation of the numerical data, the temperature distribution on the tool tip – workpiece interface, as well as the chip morphology (shape and curling radius) were determined. Results showed a good agreement between the numerical and the experimental data. Specifically, thrust force and chip morphology exhibited an agreement of about 95% and 90% respectively, which confirms the potential of 3D FEA implementation on machining investigations.

Highlights

Since drilling is one of the most used machining process, its study draws the attention of many researchers worldwide
Due to the fact that simulation of drilling was added in commercial finite element analysis (FEA) software only recently, 3D finite element modelling is an invaluable asset during related researches
Thrust force and chip morphology exhibited an agreement of about 95% and 90% respectively, which confirms the potential of 3D FEA implementation on machining investigations

Summary

Introduction

Since drilling is one of the most used machining process, its study draws the attention of many researchers worldwide. Dou et al [2] developed a new constitutive model to improve a model for prediction purposes of generated thrust force and torque in drilling. A 3D FE model for simulating the drilling process of SiCp/Al6063 was established by implementing the new constitutive model. Xiang et al [3] analyzed in their work the micro mechanisms underlying the wear of macroscale tools during diamond machining of SiCp/Al6063 composites They developed the mechanism-based diamond wear model in relation to the dominant wear behaviors. To validate the simulation model, authors investigated the flow drilling of AlSi10Mg with a non-pre-heated and pre-heated tool as well. Even though many researchers in the past few years utilized 3D FE modelling for investigation purposes of machining, 3D analysis of alloy drilling is a topic with multiple aspects that require thorough examination. The thrust force, the tool tip – workpiece temperature distribution and the chip cone radius were determined

Experimental process setup

Simulation setup

Assessment of thrust force

Assessment of chip formation and temperature distribution

Conclusions