Theoretical Model of Drilling Force Considering Geometrical Parameters of Chamfered Edge of Spade Drill

doi:10.12382/bgxb.2022.0753

Abstract

Abstract:

To provide reference for the design, development and application of the chamfered edge of the spade drill, the drilling force model of the spade drill considering the geometric parameters of the chamfered edge was established. Based on the orthogonal cutting theory, the geometric coefficient of the workpiece material deformation due to extrusion of the chamfered edge was introduced. The tangential force and normal force models of the chamfered spade drill relative to the direction of the main cutting edge were established. The axial force and torque of the spade drill were calculated according to the actual machining of its cutting edge. Considering the influence of the chip-split grooves on the drilling force of the spade drill, the deformation coefficient was used instead of shear angle and friction coefficient. The finite elements were employed to simulate the spade drilling process. The drilling force of the spade drill was tested experimentally. The axial force and torque of the spade drill were obtained. The drilling force of the spade drill with chamfered edge was compared with the drilling force of the ool with sharp cutting-edge. The results show that: the theoretical formula of drilling force established is suitable for calculating the axial force and torque of spade drills with chamfered edges; the influence law of the geometric parameters of the chamfer edge to the drilling force of the spade drill was obtained; when designing the chamfered edge of spade drills, the chamfer width of the spade drill should be 0.1mm, and the chamfer angle should be 10° or 30° to obtain a low drilling force.

Key words: spade drilling tools, chamfered edges, drilling force, theoretical model

WANG Guilin, YU Aibing, ZOU Pian, LI Yi, LI Kefan, WU Senkai. Theoretical Model of Drilling Force Considering Geometrical Parameters of Chamfered Edge of Spade Drill[J]. Acta Armamentarii, 2023, 44(6): 1733-1743.

Figures/Tables 15

Fig.1 Sectional drawing of spade drill insert and chamfered edge

Table 1 Chamfered edge parameters of spade drill inserts in drilling experiments

刀具编号	b/mm	γ/(°)	刀具编号	b/mm	γ/(°)
0	0	0	5	0.2	20
1	0.1	10	6	0.3	20
2	0.2	10	7	0.1	30
3	0.3	10	8	0.2	30
4	0.1	20	9	0.3	30

Fig.2 Drilling force test experimental devices

Fig.3 Boundary conditions and meshes of the drilling model

Table 2 Johnson-Cook material parameters of 7075-T651alloy[16]

A/MPa	B/MPa	n	C	m	$ε · 0$ /s^-1	T₀/℃	T_m/℃	d₁	d₂	d₃	d₄	d₅
527	575	0.72	0.017	1.61	1	25	635	0.110	0.572	-3.446	0.016	1.099

Table 2 Johnson-Cook material parameters of 7075-T651alloy[16]

A/MPa	B/MPa	n	C	m	$ε · 0$ /s^-1	T₀/℃	T_m/℃	d₁	d₂	d₃	d₄	d₅
527	575	0.72	0.017	1.61	1	25	635	0.110	0.572	-3.446	0.016	1.099

Table 3 Thermal and mechanical properties of 7075-T651 alloy[17]

温度/℃	导热系数/(W·m^-1·℃^-1)	密度/(kg·m^-3)	杨氏模量/GPa	热膨胀系数/℃^-1	比热/(J·kg^-1·℃^-1)	泊松比
25	130	2810	71.1	2.16×10^-5	870	0.33
100	186	2800	65.2	2.34×10^-5	910	0.33
200	197	2770	56.3	2.36×10^-5	960	0.33
300	194	2750	38.0	2.43×10^-5	980	0.33
400	196	2730	31.5	2.52×10^-5	1040	0.33
500	196	2700	25.0	2.61×10^-5	1100	0.33
532	193	2690	24.0	2.75×10^-5	1110	0.33

Table 4 Material parameters of carbide spade drill inserts[18]

导热系数/(W·m^-1·℃^-1)	密度/(kg·m^-3)	杨氏模量/GPa	热膨胀系数/℃^-1	比热/(J·kg^-1·℃^-1)	泊松比
79.6	14850	640	4.7×10^-6	176	0.22

Fig.4 Force analysis of the ideal contour of the lower boundary of the primary deformation zone

Fig.5 Flow pattern of workpiece material on the chamfered edge of the spade drill

Fig.6 Drilling force component of the cutting edge unit dW of the spade drill

Fig.7 Schematic diagram of the working principle of the chip-split grooves of the spade drill

Table 5 Values of theoretical model parameters

参数	刀具编号
参数	1	2	3	4	5	6	7	8	9
ξ	1.58	1.75	1.90	1.53	1.69	1.80	1.60	1.80	2.03
c	0.046	0.030	0.023	0.102	0.057	0.036	0.06	0.031	0.039

Fig.8 Axial forces and torques from simulation, theory and drilling experiment

Fig.9 Comparison of axial force and torque between spade drills with sharp cutting-edge and chamfered edge

Fig.10 Growth rates of axial force and torque of spade drill with chamfered edge relative to that with sharp cutting-edge

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