Cutting forces prediction and thermal distribution considering various cutting parameters and wear progression in drilling

Abstract

Purpose The purpose of this paper is to develop a finite element method (FEM) supported simulation of drilling process applied to superficially hardened steels and assess the heat treatments effect on the optimum drilling conditions (feed rate, speed, etc.). Design/methodology/approach A three-dimensional model was developed simulating the drilling procedure while experimental data, concerning the chip geometry and force components, were used to validate the model. The developed simulation will allow systematically insight on the tools wear progression induced by the developed temperature and stress fields. Two different cases of simulation were examined. A typical simulation was investigated, which erected with all the standard features found in the FEM simulation software. In the second case, all the experimental data were introduced. Findings The simulation results revealed that the advanced developed FEM model describes sufficiently the real chip geometry. Moreover, the FEM calculations provide an effective tool for predicting occurring temperatures, strain and stresses and thus for approaching the real loads of the cutting tool during drilling. Originality/value This paper fulfills an identified need to study the drilling simulation.