Abstract
This paper presents a new approach to developing the torque model in deep hole drilling, both for conventional and ultrasonic assisted drilling processes. The model was proposed as a sum of three components: the cutting, the chip evacuation and the stick-slip torques. Parameters of the new model were carried out by applying the regression analysis technique, with the correlation values higher than 0.999. The data were collected from 36 experimental dry drilling tests, both in conventional and ultrasonic assisted cutting conditions, with the depth-to-diameter of the drilled holes of 7.5. The major advantage of the new model compared to previous models is that the new model of chip-evacuation torque has only one coefficient, thus making it easier to evaluate and compare different deep-drilling processes. The effectiveness of ultrasonic assistance in deep hole drilling was also highlighted using the proposed model. The new model is promising to predict critical depth and torque in deep hole drilling.
Highlights
Aluminum alloys have been widely used in applications where materials with high strength-to-weight ratio are required, especially in the rapidly growing automobile and aerospace industries
The effectiveness of ultrasonic assisted drilling (UAD) regarding the reduction of chip evacuation torque, leading to machinability improvement in ultrasonic assisted deep drilling of aluminum alloy 6061, has recently been found in several experimental studies of Nguyen and Chu [28,29,30,31]
This paper implemented a new approach to develop a practical model of drilling torque in deep
Summary
Aluminum alloys have been widely used in applications where materials with high strength-to-weight ratio are required, especially in the rapidly growing automobile and aerospace industries. Sahu et al [16] evaluated several improvements of chip evacuation criteria in terms of critical depth, chip segmentation, thrust force and torque reduction of groove-type chip breakers on a twist drill Another model similar to the Mellinger et al attempt was applied in the drilling of bone for orthopedic surgery [18]. The effectiveness of UAD regarding the reduction of chip evacuation torque, leading to machinability improvement in ultrasonic assisted deep drilling of aluminum alloy 6061, has recently been found in several experimental studies of Nguyen and Chu [28,29,30,31]. The new approach to modeling the chip evacuation torque is developed, providing a more convenient way to predict drilling torque and to compare the effectiveness of both conventional and ultrasonic assisted deep drilling
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