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TECHNOLOGY REVIEWS

Automated Drill Modeling for Drilling Process Simulation

[+] Author and Article Information
Athulan Vijayaraghavan

Laboratory for Manufacturing and Sustainability, University of California at Berkeley, 1115 Etcheverry Hall, Berkeley, CA 94720-1740athulan@berkeley.edu

David A. Dornfeld

Laboratory for Manufacturing and Sustainability, University of California at Berkeley, 1115 Etcheverry Hall, Berkeley, CA 94720-1740dornfeld@berkeley.edu

J. Comput. Inf. Sci. Eng 7(3), 276-282 (Jul 09, 2007) (7 pages) doi:10.1115/1.2768091 History: Received September 15, 2006; Revised July 09, 2007

Accurate models of two-flute conical twist drills are needed for finite element simulations of the drilling process. Existing drill designing methods rely extensively on discretized analytical equations to describe the drill and different sets of equations that need to be formulated as the drill design changes. This paper presents a method to create accurate models of two-flute conical twist drills using solid-modeling techniques, which addresses some of these shortcomings. Boolean operations are used to mimic the drill manufacturing steps and generate the fully designed drill. The drills generated by this method have been used in finite element simulations to study the effect of drill point geometry on burr formation in drilling.

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Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 1

Geometry of two-flute twist drill (adapted from (7))

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Figure 2

Drill coordinate system

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Figure 3

Flute cross section for different drills (a: p=118deg, h=30deg; b: p=118deg, h=45deg; c: p=135deg, h=30deg; r=5mm,W=1.8mm for all drills)

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Figure 4

Coordinate system for drill flank grinding (17)

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Figure 5

Grinding cone and drill flank

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Figure 6

Modeling procedure: The flute cross section (A) is swept to create the solid flute (B). The total volume swept by the left cone is (C) and this removes the volume (D) from the flute. The fully modeled drill is shown in (E), after both the cones have removed volume.

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Figure 7

Drills ground with a 32deg (left) and 30deg cone (right)

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Figure 8

Stress state in drilled workpiece for drills of different point angles (4)

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Figure 9

Drill (left) meshed in different FEM packages (center: ABAQUS ; right: DEFORM )

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