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Mechanistic modeling of micro-drilling cutting forces

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Abstract

This paper presents a mechanistic model for micro-drilling cutting forces that includes the cutting edge radius and the minimum chip thickness size effects. The proposed model considers three different cutting regions, i.e., ploughing-dominant, transition, and shearing-dominant, based on these size effects. Specific normal force and specific friction force coefficients have been determined through model calibration using micro-drilling experimental results. Model is validated with micro-drilling experimental results of different cutting conditions and of different machining environments. Comparisons of model simulated and experimental results show that ploughing force contributions are significant, especially at low feed rates. The proposed model has also been applied to characterize size effects in micro-drilling.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Birla Institute of Technology, Patna campus, Patna, 800014, India

    Ravi Shankar Anand

  2. Department of Mechanical Engineering, Indian Institute of Technology Patna, Bihta, Patna, 801103, India

    Karali Patra

  3. Institute of Machining Technology, TU Dortmund, Dortmund, 44227, Germany

    Markus Steiner & Dirk Biermann

Authors
  1. Ravi Shankar Anand
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  2. Karali Patra
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  3. Markus Steiner
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  4. Dirk Biermann
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Corresponding author

Correspondence to Karali Patra.

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All professional ethics have been followed. The manuscript has not been submitted to other journal for simultaneous consideration. The manuscript has not been published previously (partly or in full). No data has been fabricated or manipulated and no data, text, or theories by others are presented as if they were the author’s own. Proper acknowledgements to other works have been given. Consent to submit has been received explicitly from all co-authors. Authors whose names appear on the submission have contributed sufficiently to the scientific work and therefore share collective responsibility and accountability for the results.

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There is no conflict of interest in this work.

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Anand, R.S., Patra, K., Steiner, M. et al. Mechanistic modeling of micro-drilling cutting forces. Int J Adv Manuf Technol 88, 241–254 (2017). https://doi.org/10.1007/s00170-016-8632-2

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  • DOI: https://doi.org/10.1007/s00170-016-8632-2

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