Comparison of Johnson-Cook Material Model and Software Library Results in Finite Element Analysis of the Effect of Drill Bit Geometry on the Drilling of AISI 4140 Steel

Abstract

In this study, the effects of the elements constituting the drill bit geometry—the notch angle, core thickness, and splitting angle on the drillability of AISI4140 steel were analyzed using finite element-based simulations. In the simulation studies, 6.8 mm diameter, double-fluted, helical, split-tip, and solid carbide drill models were used. These models were varied with notch angles of 30°, 45°, and 60°, core thicknesses of 0.5 mm, 1.0 mm, and 1.5 mm, and splitting angles of 120°, 135°, and 150°. In the study, simulations were performed by selecting the AISI4140 steel available in the software library and by defining the Johnson-Cook material model of AISI4140 steel in the software, and the results obtained (thrust force, drilling torque, temperature values, stress generated in the drills, chip shape) were compared. The similarity rates of the data obtained from the drilling simulations of both the JC material model and the material selected from the software library are approximately 80% and above. When effect graphs were created for all data using a full factorial design, the optimal drill geometries were determined to be the G24-coded drill according to the JC material model and the G15-coded drill geometry when the material was selected from the software library. It was also determined that the chip shapes formed as a result of drilling both materials were quite similar.

Keywords

• AISI4140
• Drilling
• Drill Bit Geometry
• Machinability
• Finite Element Method

AISI 4140 Çeliğinin Delinmesinde Matkap Uç Geometrisi Etkisinin Sonlu Elemanlar Analizinde Johnson-Cook Malzeme Modeli ve Yazılım Kütüphanesi Sonuçlarının Kıyaslanması

Öz

Bu çalışmada, AISI4140 çeliğinin delinmesinde matkap uç geometrisini oluşturan unsurlardan; batma açısı, öz kalınlığı ve giriş açısının delinebilirlik üzerindeki etkileri sonlu elemanlar destekli simülasyonlarla analiz edilmiştir. Simülasyon çalışmalarında, 6.8 mm çapında, iki ağızlı, helisel yapıda, split uçlu ve yekpare karbür matkap modelleri kullanılmıştır. Bu modellerde; batma açıları 30°, 45° ve 60°, öz kalınlıkları 0,5 mm, 1,0 mm ve 1,5 mm, giriş açıları ise 120°, 135° ve 150° olacak şekilde çeşitlendirme yapılmıştır. Çalışmada hem yazılım kütüphanesinde hazır bulunan AISI4140 çeliği seçilerek, hem de AISI4140 çeliğinin Johnson-Cook malzeme modeli yazılıma tanımlanarak simülasyonlar yapılmış ve elde edilen sonuçlar (itme kuvveti, delme momenti, sıcaklık değerleri, matkaplarda oluşan gerilim, talaş şekli) kıyaslanmıştır. Hem JC malzeme modelinin hem de yazılım kütüphanesinden seçilen malzemenin delme simülasyonları sonuçlarından elde edilen verilerin benzerlik oranları yaklaşık %80 ve üzerindedir. Tüm verilerin tam faktöriyel olarak etki grafikleri oluşturulduğunda optimum matkap geometrilerinin; JC malzeme modeline göre G24 kodlu matkap, yazılım kütüphanesinden malzeme seçildiğinde ise G15 kodlu matkap geometrisi sonucuna ulaşılmaktadır. Her iki malzemenin delinmesi sonucunda oluşan talaş şekillerinin de oldukça benzer olduğu tespit edilmiştir.

Anahtar Kelimeler

• AISI4140
• Delme
• Matkap Uç Geometrisi
• İşlenebilirlik
• Sonlu Elemanlar Metodu

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