Feasibility Studies for an Enhanced Flat Bottom Drill Tool Design Considering Modal and Resonance Using Finite Element Methods

Yıl 2022, Cilt: 3 Sayı: 2, 46 - 63, 11.01.2023

Nima Zoghipour Yusuf Kaynak

Öz

Design of a cutting tool necessitates a comprehension of the applications and quandaries that may come across from manufacturing to the machining process. Developing technologies in components with complicated features and the competition among manufacturers in rapid and precision production leads to design and application of new types of cutting tools with sophisticated geometries. Besides sufficient cutting performance and dimensional accuracies, these tools are required to have setup rigidity, static and dynamic strength to prevent any damages to themselves, holders, and machine components. In this paper, flat bottom drills with various axial and radial rake angles have been designed and subjected to modal analyses using finite element methods. The first six natural frequencies, maximum total displacements, stiffnesses as well as the period of oscillation corresponding to the modes shape have been calculated for the designed tools. Based on the obtained results, it is seen that the designed flat bottom drills have acceptable stiffnesses and natural frequencies to be utilized in machining processes. Radial rake angle has a noticeable influence on the natural frequencies and stiffnesses of the system.

Anahtar Kelimeler

Flat bottom drill, modal analyses, natural frequency, finite element methods.

Destekleyen Kurum

TÜBİTAK

Proje Numarası

118C069

Teşekkür

The authors thank TUBITAK (The Scientific and Technological Research Council of Turkey) for partially supporting this work under project number 118C069.

Kaynakça

• [1] O. Isbilir, E. Ghassemieh, Finite element analysis of drilling of titanium alloy, Procedia Engineering 10 (2011) 1877–1882
• [2] https://www.nachiamerica.com/1-21/Cutting-Tools/Catalogs/General/
• [3] M. Zapciu, O. Cahuc, C. F. Bisu, A. Gérard, J. Y. K'nevez, Experimental study of machining system: dynamic characterization, J. of Machin. and Form. Technol. 1, 3-4 (2009) 1-18
• [4] K. Ahmadi, Y. Altintas, Stability of lateral, torsional and axial vibrations in drilling, International Journal of Machine Tools & Manufacture 68 (2013) 63–74
• [5] S. Ema, H. Fujii, E. Marui, Chatter vibration in drilling, journal of engineering for industry, November 1988, Vol. 110/309
• [6] Y. Zhai, H. Song, J. Hu, Study on plunge milling cutter design with finite element analysis, Materials Science Forum, Vols. 836-837, pp 425-429
• [7] H. Fujii, E. Marui, S. Ema, 1986b. Whirling vibration in drilling. Part 2: influence of drill geometries, particularly of the drill flank, on the initiation of vibration. Journal of Engineering for Industry, 108: 163-1168.
• [8] H. Fujii, E. Marui, S. Ema, 1988. Whirling vibration in drilling. Part 3: vibration analysis in drilling workpiece with a pilot hole. Journal of Engineering for Industry, 110: 315-321
• [9] O. Tekinalp, A.G. Ulsoy, Modeling and finite element analysis of drill bit vibrations, Journal of vibration, acoustics, stress, and reliability in design, 111 (2) (1989) 148–155.
• [10] A. Razika, A. Idriss, Frequency analysis of the tool with and without wear during turning by modal analysis, Journal of Material Sciences & Engineering, 2018, 7:3
• [11] S. Y. Ji, X. L. Liu, F. G. Yan, C. X. Yue, X. F. Zhao, Layer face milling cutter parametric modeling and modal analysis, Advanced materials research vols. 102-104 (2010) pp 605-609
• [12] K. R. Kashyzadeh, S. Ghorbani, Numerical study of free vibration behaviour of filled tool holder using epoxy-granite,
• [13] L. Liu, Z. Shi, Z. Liu, Finite element modal analysis for face-milling cutter, Key engineering materials Vols 589-590 (2014) pp 19-22
• [14] Tobias, S. A., "Machine-Tool Vibration," Blackie, 1965.
• [15] https://community.sw.siemens.com/s/article/Natural-Frequency-and-Resonance