Machining prediction of spindle–self-vibratory drilling head

Abstract

The drilling of deep holes with small diameters remains an unsatisfactory technology, since its productivity is rather limited. The main limit to an increase in productivity is directly related to the poor chip evacuation, which induces frequent tool breakage and poor surface quality. Retreat cycles and lubrication are common industrial solutions, but they induce productivity and environmental drawbacks. An alternative response to the chip evacuation problem is the use of a vibratory drilling head, which enables the chips to be fragmented thanks to the axial self-excited vibration. Contrary to conventional machining processes, axial drilling instability is sought, thanks to an adjustment of head design parameters and appropriate conditions of use. A dynamic high-speed spindle/drilling head/tool system model is elaborated on the basis of rotor dynamics predictions. In this paper, self-vibratory cutting conditions are established through a specific stability lobes diagram. Investigations are focused on the drill's torsional–axial coupling role on instability predictions. A generic accurate drilling force model is developed by taking into account the drill geometry, cutting parameters and effect of torsion on the thrust force. The model-based tool tip FRF is coupled to the proposed drilling force model into an analytical stability approach. The stability lobes are compared to experimentally determined stability boundaries for validation purposes.