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A hybrid modelling approach for characterizing hole shrinkage mechanisms in drilling Ti6Al4V under dry and cryogenic conditions

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Abstract

Hole shrinkage is a common phenomenon in drilling difficult-to-cut materials like Ti6Al4V due to their poor thermal properties and high elasticity, which can lead to increase in tool wear and decrease in surface integrity. In this study, an in-depth analysis of hole shrinkage mechanism is carried out through a hybrid modelling approach for both dry and cryogenic cutting conditions. The plastic deformation induced by chip formation and tool-workpiece interaction is treated as equivalent thermomechanical loads, and heat convection conditions are described along tool path in order to perform details in heat transfer process for both cases. Quantitative analysis is presented through numerical simulation and experimental data of temperature and deformation along hole contour to analyze deformation components in order to reveal the hole shrinkage mechanism. Additional interactions between cutting tool and workpiece material are induced by recovery of elastoplastic deformation, and plastic portion is a more devastating factor in tool wear and surface damage induced by hole shrinkage. This study presents an in-depth and fundamental understanding of the hole shrinkage mechanism through a hybrid modelling approach, which can characterize heat transfer process during machining for both dry and cryogenic conditions, and simulation of this fully coupled thermomechanical cutting process with supply of coolants was rarely reported in previous research. The results show that plastic deformation induced hole shrinkage can enhance the interaction between workpiece material and cutting tool, and cryogenic assistance presents a good performance in restricting this kind of phenomenon. The related results could be used to optimize strategies of eliminating hole shrinkage with cryogenic assistance in industrial applications.

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Data availability

All data generated or analyzed during this study are included in this article.

Abbreviations

D :

The drill diameter (mm)

l :

The height of drill tip (mm)

d :

Projection distance of nozzle (mm)

ϕ :

The nozzle diameter (mm)

φ 2 :

The projection angle (°)

A, B, C :

VPL model parameters regarding strain hardening

n :

VPL model parameter regarding strain rate hardening

v :

VPL model parameter regarding thermal softening

T r :

Reference temperature (K)

h :

The height of contact (mm)

w :

The width of margin (mm)

Δh :

Incremental height per tooth per revolution (mm/r)

σ :

Normal stress (MPa)

τ :

Tangential stress (MPa)

μ l :

Friction coefficient of main edge

μ h :

Friction coefficient of margin

F r :

Radial force (N)

F t :

Tangential force (N)

F f :

Feed force (N)

Λ 1 :

Percentage of shearing energy transformed into heat

Λ 2 :

Percentage of heat produced during chip formation and transformed into machined surface

Λ 3 :

Heat partition coefficient at the interface of tool-workpiece

D l- flux :

Heat flux intensity of main cutting edge area (W/mm2)

D h- flux :

Heat flux intensity of margin area (W/mm2)

ɛ, β, γ, δ, i, j, k, m :

Controlling parameters for calculating heat convection coefficient

ϕ ref, P ref, D ref, α ref :

Referencing values of nozzle diameter, projection pressure, projection distance and projection angle

P :

Driven pressure of LN2 applied in experiments (Bar)

α :

Projection angle of LN2 (°)

a, b :

Intermediate variables for calculating distribution of heat convection coefficient

t :

The current time step during machining process (s)

x(t), y(t), z(t) :

The coordinates of margin along x-, y-, and z-axis at the current time t

T N :

Time required for a single rotation (s)

z 0 :

Initial position of tool along z-direction (mm

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Acknowledgements

The authors would like to acknowledge Camille Robert from LAMPA, Arts et Métiers ParisTech Angers for his kind help in assistance of using the computational clusters.

Funding

This research was fully funded by Institute Carnot ARTS.

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Authors and Affiliations

  1. Arts et Metiers Institute of Technology, LaBoMaP, Université Bourgogne Franche-Comté, HESAM Université, Rue Porte de Paris, 71250, Cluny, France

    Hongguang Liu, Hélène Birembaux, Frédéric Rossi & Gérard Poulachon

  2. Arts et Metiers Institute of Technology, LAMPA, HESAM Université, 2 Boulevard du Ronceray, 49035, Angers, France

    Yessine Ayed

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Contributions

Hongguang Liu: methodology, data curation, formal analysis, validation, visualization, writing—original draft, reviewing & editing. Hélène Birembaux: Methodology, Data curation, Supervision, Writing – review & editing. Yessine Ayed: Methodology, Formal analysis, Supervision, Writing – review & editing. Frédéric Rossi: Validation, Data curation, Supervision, Writing – review & editing. Gérard Poulachon: Conceptualization, Funding acquisition, Project administration, Supervision, Writing – review & editing.

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Correspondence to Hongguang Liu.

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Liu, H., Birembaux, H., Ayed, Y. et al. A hybrid modelling approach for characterizing hole shrinkage mechanisms in drilling Ti6Al4V under dry and cryogenic conditions. Int J Adv Manuf Technol 118, 3849–3868 (2022). https://doi.org/10.1007/s00170-021-08229-2

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