Numerical modelling of the BTA deep hole drilling process

Abstract

The BTA deep hole drilling process is applied in order to produce bores with a large length to diameter ration at comparably high diameters of the bores. During drilling, first, the bore is cut by the cutting edge and shortly after that, a guide pad slides over the newly produced bore wall, burnishing the surface. These two effects condition the bore wall and alter its surface integrity depending on the process parameters. In the past, extensive destructive and non-destructive tests were conducted to obtain information on the surface integrity of the machined parts. Furthermore, a large number of in- and off-process measurements were carried out in material and cost-intensive experiments to determine values such as residual stresses or white etching layers. The presented work shows different finite element models of the BTA deep hole drilling process using continuous remeshing and, in order to reduce the calculation times, the Coupled Eulerian-Lagrangian (CEL) method as well. The results simulated based on this models comprise temperatures, process forces and surface properties that are compared to measured values from pervious works for validation. The various approaches are evaluated to determine whether they predict the bore hole surface integrity and thus support future investigations.