Mathematical modelling of stress on the cutting tool in drilling

The formation of chip in metal cutting is the result of plastic deformation which processes high strains and temperature effects. In the last 30 years many studies have taken place on the subject of cutting mechanics with the purpose in some of the models is successfully defined correct solutions in some have yet been proved. This study aims to experimentally determinated cutting forced occurred in drilling process which have an important role in metal cutting. It also aims to analyze stresses which occur on cutting tools in effect of these measured cutting forced using the finite element method, and to developed a mathematical model for defining these stresses that have been analyzed. With this purpose, AISI 1050 has been chosen as the material used in the tests carried out in the first stage. Samples prepared this material have been drilled 20 mm diameter and 20 mm at the CNC vertical machining centre using Mitsubishi UP20M quality GPMT070204-U1, GPMT070204-U2 and GPMT070204-U3 type inserts and TAWN200TVP15TF type solid insert. During drilling, cutting forces occurred after applying five different cutting speeds and two feedrates to each tool have been the measured using a KISTLER 9272 type dynamometer. With the impact of these forces the stresses on the cutting tools have been analyzed with the finite element method based ANSYS 6.1 software. In the third stage in line with the experimental data and analyses the models have been generated. For this purpose the MATLAB software has been used.The study concludes stress components have been increased due to cutting forces which rise in parallel to increases in cutting speed and feed rates. In terms of stress distributions, since stresses for both tool groups are concentrated around a small area, point contact shaped stress behaviors can be observed. Also observed is a close relationship between the stress results obtained with ANYSY and stress components calculated with the model developed. Finally, the study shows that these models can be applied in practical applications which use various cutting parameters for these tools.