Development of a force and temperature twist drill model for AISI 1020 steel

A three-dimensional model of the drilling process is developed in this dissertation. The model can be used to predict the thrust force and drilling torque as well as the temperature contours within the drill body for a specific drill point geometry, cutting conditions, and workpiece material.; The model is based on representing cutting along the cutting lips as a collection of oblique sections. Similarly, cutting in the chisel edge region is represented as orthogonal cutting. For each section, a two-dimensional finite element model is used to simulate the cutting process. The finite-element model predicts the chip geometry, tool forces, and temperatures in the chip, workpiece, and tool. The two-dimensional sections are combined to determine the overall thrust force and drill torque. Drill temperatures are calculated by applying the heat flux to a three-dimensional solid model of the drill point and body.; The model was verified by comparing predicted cutting forces with measured forces in orthogonal, oblique, and drilling tests. Drilling experiments were preformed on AISI 1020 steel for several drill diameters, spindle speeds, and feed rates. Good agreement was found between measured and predicted forces for all tests.