In this paper, a chip-evacuation force model is presented to predict the torque and thrust required to evacuate the chips during drilling for various flute geometries. The model considers the chips in the flutes as granular solids and determines the chip-evacuation thrust and torque from the normal and lateral pressure distributions in the chips that fill the flutes. The model requires two coefficients of friction that are established via a calibration procedure. The critical depth for the process is determined by setting a threshold value on the chip-evacuation torque, which is based on the onset of chip-clogging. The effectiveness of the chip-evacuation force model in determining the chip-evacuation thrust and torque and predicting the critical depth has been assessed via a set of validation experiments using both standard and parabolic drills. The parabolic drill produced lower chip-evacuation forces and increased critical depths relative to the standard drill. While the standard drill has a modestly larger effective flute cross-sectional area for most of the flute length, the parabolic drill has a significantly smaller contact area between the chips and the flute surface, which is the main reason for the superior chip-evacuation performance of the parabolic drill.
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August 2003
Technical Papers
Modeling Chip-Evacuation Forces in Drilling for Various Flute Geometries
Jeffrey C. Mellinger, Graduate Research Assistant,
Jeffrey C. Mellinger, Graduate Research Assistant
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801
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O. Burak Ozdoganlar, Post Doctoral Research Associate,
O. Burak Ozdoganlar, Post Doctoral Research Associate
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801
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Richard E. DeVor, Professor,
Richard E. DeVor, Professor
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801
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Shiv G. Kapoor, Professor,
Shiv G. Kapoor, Professor,
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801
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Jeffrey C. Mellinger, Graduate Research Assistant
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801
O. Burak Ozdoganlar, Post Doctoral Research Associate
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801
Richard E. DeVor, Professor
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801
Shiv G. Kapoor, Professor,
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received September 2001; Revised November 2002. Associate Editor: Y. C. Shin.
J. Manuf. Sci. Eng. Aug 2003, 125(3): 405-415 (11 pages)
Published Online: July 23, 2003
Article history
Received:
September 1, 2001
Revised:
November 1, 2002
Online:
July 23, 2003
Citation
Mellinger, J. C., Ozdoganlar, O. B., DeVor, R. E., and Kapoor, S. G. (July 23, 2003). "Modeling Chip-Evacuation Forces in Drilling for Various Flute Geometries ." ASME. J. Manuf. Sci. Eng. August 2003; 125(3): 405–415. https://doi.org/10.1115/1.1578671
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