Mini Project 2021-22 6/12/2022

“Experimental Analysis and Simulation

of drilling forces ”
by
1) Abhishek Hiwale : 111913004
2) Adinath Dhamdhere : 111913005
3) Chaitanya Patil : 111913020
4) Naresh Shingote : 111913039
5) Peddi Reddy Akki : 111913041
Under the guidance of
Dr. M.S. Sawant

College of Engineering Pune 1

(An Autonomous Institute of the Govt. of Maharashtra)
Contents:
1) Objectives of this project
2) Literature Review
3) Introduction
4) Design of drill bit
5) Simulation of drilling process on Ansys software
6) Thrust force graphs of simulation
7) Experimental verification of thrust forces in lab
8) Experimental graphs of thrust force on dynamometer
9) Results
10)Future Scope
11)Conclusion
12) References
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 1. Objectives of the project :

 To identify the factors that influence the machining mechanics i.e Thrust Force like as
feed rate, speed of spindle, size of drill tool, leap angle, lubricants etc.
 To study the simulation of the drilling operation on Ansys software for the stress.
 To analyze experimentally various drilling forces in laboratory using VMC and
dynamometer.
 To perform drilling tests changing the feed rate, rpm, lubrication on same metal and
to capture the thrust force signal/graph for thrust force analysis.

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2. Literature review :
Researchers ( Year)
Taylor et al. ( 2013)
Kurt et al. (2014)
Zheng,X.; Liu,Z et al. (2013)
Hong,Y.; Yoon,H.; Moon et al.
(2014)
Remarks
Studied the role that temperature plays in metal cutting processes was
first studied from an experimental point of view, that increasing cutting
speeds entails an increase in tool temperatures and consequently a
decrease in tool life.
Studied the impact of cutting speed, point angle, and coating materials
on different characteristics of drill tool.
Estimated various techniques to upgrade the dull parameters for
diminishing burr size
Examined The impacts of diverse parameters like bore Temperature ,
drill diameter ,spindle speed and feed on the space traits parameterized
with the aid of burr.
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3. Introduction :
Drilling process :
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials.

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 Drill bit and drilling forces :
Drill bits are cutting tools used to create cylindrical holes, almost always of circular cross-
section.

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 4. Design of drill bit :
Drill bit design specification HSS Properties of drill bit material :
tool :
bit type – twist bit
Lip angle – 135
bit dia. – 6mm
Flute length – 75mm
Shank length – 55 mm

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Drill bit design procedure on Fusion 360 :

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5. Simulation of drilling operation on Ansys software :

• ANSYS Mechanical APDL was used.

• To match the realistic situation, this research
used Explicit Dynamics module.

Process Steps for FEA Analysis

Geometry creation
Mesh Generation

Process steps for FEA Analysis

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Boundary Conditions
The following are the descriptions for each boundary conditions used in
this simulation:
 Engineering Data
 Fixed Support
Remote Displacement
 Velocity
End Time- To ensure the drilling tool can completely drill through the
Aluminum work-piece, the End time is set to be 0.0001 second.

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Simulation of drilling process on Ansys:

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6. Graphs of simulation process on Ansys :

For a drill of 6 mm diameter, Point angle-118 degrees, Helix angle-45 degrees

1) Feed rate-50mm/min and Angular speed-1000 RPM

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2) Feed rate-50mm/min and Angular speed-2000 RPM

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For 6mm drill, Lip angle-130 degrees, Helix angle-38 degrees

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7. Experimental verification of thrust forces in lab :

a. Set up the drilling tool.

b. Set various drilling parameters in the KERN machine computer.
c. Load the spot drill from the tool changer and calibrate the tool diameter and shank length.
d. Start to rotate the spindle with the spot drill for the pre-drill action.
e. Set spindle movement in Z-axis for 0.1mm pre-drill depth
f. Set the desired period of time (second) for Kistler Dynamometer data recording
g. Switch on the cooling/lubricating liquid to avoid the tool failing by friction.
h. Start to rotate the spindle with the twist drill and use the Z-axis with spindle movement for
drilling process.
i. Before the drill touches the work-piece, start the recording of drilling force data by Kistler
dynamometer.
j. Stop the spindle rotation once the drilling is finished. Switch off the liquid and send back the
twist drill to tool changer.
k. Load the next twist drill from tool changer and repeat the step.
l. Finish all drilling process, remove the work-piece from the fixture and clean the work-piece by
compressed air. 16
 Overall Setup for the experiment :

Specimen of Aluminium clamped on VMC m/c All connections made for dynamometer Dynamometer Setup
and it's output on monitor

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Experimental readings and results :
Expt. No Spindle Speed Feed - f
(in rpm) (mm/min)

1 1000 50

2 2000 50

3 3000 50

4 2000 25

5 2000 75

6 2000 (With Oil) 50

7 1000 (With Oil) 50

8 3000 (With Oil) 50

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Experiment perform in Laboratory :

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 Drilling Process

Graphs on Dynamometer 20
Chip Removal in Drilling
8. Thrust force graphs for all the readings
:Experiment No. 1
Feed rate : 50 mm/min
Rotation : 1000 rpm
On X-axis : 10,000 Units = 1 second

Chart Title
700

600

500

400

300

200

100

0
120 4940 9760 14580 19400 24220 29040 33860 38680 43500 48320 53140 57960 62780 67600 72420 77240 82060 86880 91700 96520 101340106160110980115800
-100

Time s Fz N

Mean Thrust Force (Fz) : 273.805308 N 21

Experiment No. 2
Feed rate : 50 mm/min
Rotation : 2000 rpm
On X-axis : 10,000 Units = 1 second

Mean Thrust Force(Fz) : 140.805308 N

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Experiment No. 3
Feed rate : 50 mm/min
Rotation : 3000 rpm
On X-axis : 10,000 Units = 1 second

Mean Thrust Force(Fz) : 110.3274 N

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 9. Results :
1. Effect of change in feed rate on thrust force ( Keeping rpm constant)

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2. Effect of change in rpm on thrust force ( Keeping feed rate constant)

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3. Effect of change in rpm on stress ( Keeping feed rate constant)

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4. Effect of lubricant on thrust force ( Keeping feed rate constant)

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5. Effect of change in leap angle on thrust force ( Keeping feed rate and rpm constant)

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6. Chip study ( Keeping feed rate constant and rpm changing)

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10. Future Scope

 To study the forces by changing other parameters too like flute length, helix
angle, shank angle, margin, material of the tool and many more.
 To study the chips getting after the drilling process to find various relations.
 To study the wear of the tool by observing drilling holes and chips.
 To study the various forces acting in drilling on various metals that we used.
 To study of the local forces along a cutting edge.
 To studying the drilling failures using thrust force, torque and stresses
And many more…….

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 11. Conclusion :
1) As we increased the feed rate, the thrust force
increases.
2) As we increased the rpm, the thrust force decreases.
3) As we increased the rpm, the Stress at the point
decreases
4) By using the lubricant, thrust force is get decreases.
5) As we increase the leap angle, the thrust force
increases.

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12. References:
1) Parameters affecting mechanical and thermal responses in bone drilling: A review.Lee J, Chavez CL,
Park J.J Biomech. 2018 Apr 11;71:4-21. doi: 10.1016/j.jbiomech.2018.02.025. Epub 2018 Mar
1.PMID: 29559242 
2) L. Zheng, H. Zhou, C. Gao, J. YuanHole drilling in ceramics/Kevlar fibre reinforced plastics double-
plate composite armor using diamond core drill
3) N. Feito, J. Diaz-Á lvarez, J. Ló pez-Puente, M.H. MiguelezNumerical analysis of the influence of tool
wear and special cutting geometry when drilling woven CFRPs. Compos. Struct., 138 (2016),
pp. 285-294
4) N.S. Mohan, A. Ramachandra, S.M. KulkarniInfluence of process parameters on cutting force and
torque during drilling of glass-fibre polyester reinforced composites. Compos. Struct., 71 (2005),
pp. 407-413
5) Puneeth H V, Smitha B S, “Studies on Tool Life and Cutting forces for drilling operation using Uncoated
and coated HSS tool”, International Research Journal of Engineering and Technology (IRJET), Volume 4
Issue 6, June - 2017.
6) A. Attanasio, F. Fainia, J.C. Outeirob, “FEM simulation of tool wear in drilling”, 16th CIRP Conference on
Modelling of Machining Operations, ScienceDirect, 2017.
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