Prediction model optimization, simulation, and experimental verification based on the material characteristic and dynamic angle on thrust force and torque in drilling GJV450

Abstract

Abstract Compact graphite cast iron (CGI) is utilized extensively in the production of vehicle engines because it has numerous thermo-mechanical benefits. The main issues with CGI drilling are typically tied to changes in material properties, strong drilling forces, and limited tool lives. As a result, it is important to comprehend and anticipate the thrust forces and torques produced during CGI drilling. In this study, a prediction model for GJV450, a kind of CGI, is given that considers both the thermal softening of the material and the dynamic changes in the tool operating angle during the machining process. It is based on an optimized constitutive model. Finally, a three-dimensional finite element model is optimized utilizing the new constitutive model to simulate the drilling process of GJV450. Comparisons between the experimentally observed thrust forces, torques, and chip morphology are made with the results of simulations and predictions. The results show that the projected results are more in line with the experimental results than the models used by commercial FE software and that the thrust force error is reduced by 5.5% and the torque error is decreased by 19.13%.