Twist drilling SPH simulation for thrust force and torque prediction

Abstract

Abstract Drilling is one of the most common processes in metalworking. The cutting forces that occur during the drilling process have a significant impact on the accuracy and quality of the holes. Uncompensated radial cutting forces lead to an increase in the diameter of the hole being machined, which reduces its accuracy. And when machining laminated materials, excessive axial cutting force leads to a stratification of the composite and reduces the quality of the hole. In this regard, the task of determining or predicting cutting forces is currently quite relevant. This article proposes a method for calculating cutting forces when drilling aluminum homogeneous and isotropic alloy 6061-T6 using smoothed particle hydrodynamics method (SPH). The calculation results are compared with calculations using empirical formulas and the results of experiments of other authors. The influence of the chip separation criterion type and material model on cutting forces during drilling were also investigated.