Simulation of drilling operation and examination of mechanical stresses according to variation in cutting parameters in drilling operations

In this study, it is aimed to improve the cutting performance of the cutting tool (drill) used in drilling. The study includes experimental determination of thrust force and torque occurred during drilling, and analysis of the effects of these cutting loads on cutting tool with the Deform-3D program based on finite element method (FEM). For this purpose, various drilling experiments with uncoated and TiAlN/TiN coated carbide drills are conducted on full solid and pre-drilled AISI 1050 samples using different cutting parameters (cutting speeds of 60, 75, 90, 108 m/min and feed rates of 0.15, 0.20, 0.25 mm/rev). Kistler 9272 type dynamometer was used to measure the thrust force and torque occurring during the drilling experiments. The stress effects of the experimentally measured thrust force and torque on the drill were analyzed. To improve the performance of the drill, the drilling operation was simulated and the relationships between cutting parameters and stresses were investigated using the Pre, Simulator and Post modules in the Deform3D program. The results obtained with the simulations were found to be in parallel with the results measured by the experiments. By evaluating the results obtained from the study, when the cutting parameters to be determined were selected, it made significant contributions to the improvement of the cutting performance of the cutting tool and the selection of the optimum cutting parameters. The stress analysis approach applied in the study can also be applied to other cutting operations such as turning and milling. It is clear that the analysis to be made in the cutting tool design is one of the most important criteria that determine the tool performance and must be taken into account.