The investigation on the machining process of BTA deep hole drilling

The investigation on the machining process of

BTA deep hole drilling

C.H.Gao a ,K.Cheng a,*,

D.Kirkwood b

a

School of Engineering,Leeds Metropolitan University,Calverley Street,Leeds LS13HE,UK

b

Department of Engineering,Glasgow Caledonian University,Cowcaddens Road,Glasgow G40BA,UK

Abstract

In this paper,a computer-based approach is presented to the investigation of machining mechanisms in boring and trepanning association (BTA)deep hole drilling processes.The cutting mechanisms investigated are focused on the chip deformation and associated drilling forces in deep hole situation in particular.The machining models are further investigated for such processes.The models are evaluated and validated based on the data acquired with a computer-based acquisition system.It is found that the chip deformation cut by the centre edge is the largest,whereas the change tendency of the cutting force and the sum of chip deformation cut by three blades of drill are about the same.This paper also describes the measurement and analysis of the forces including the axial force in BTA deep hole machining.#2000Elsevier Science B.V .All rights reserved.

Keywords:BTA deep hole drilling;Chip deformation;Cutting force;Wear

1.Introduction

In machining processes such as turning,milling and shaping,a large chip discharge space is normally available and the chip breaker is often big enough to ensure the chip discharging.But in the process of drilling,deep hole drilling in particular,no suf?cient discharging space is available,and so peck drilling,axial vibration and pressurised cutting ˉuid are often used to help chip discharging.A satisfactory chip discharge is essential for implementing successful deep hole drilling.

The interaction between the drilling tool and the work-piece in BTA deep hole machining has been studied to determine the inˉuence of various machining conditions on the chip deformation,cutting forces and the tool wear [1±3].Since the resultant drilling force in axial direction consists of the cutting force,ˉuid pressure force,burnishing force and friction,using a complete theoretical approach based on derived equations to precisely estimate the resul-tant force would be dif?cult and impractical [4].

In this paper an experiment based approach is proposed to investigate the BTA deep hole drilling process.The inves-tigation is focused on the chip deformation,tool wear and the associated drilling forces.A computer-based data acqui-sition system and an optical ?bre force sensor is used for sampling the machining data.This study is essential for further developing an on-line monitoring system for con-trolling the machining process.

2.Experimental procedure and equipment

The experimental system is mainly composed of the deep hole drilling machine tool and the data acquisition/analysis system as shown in Fig.1.The system details are as follows:1.Cooling system:

cutting fluid flow rate,q 100l a min; cutting fluid pressure,p 2X 50MPa; cooling liquid,emulsions.

2.Sensor:optical ?bre force sensor.

3.Small signal ampli?er: accuracy,1%;

response frequency,2kHz; output draft amount,<2mV .4.Drill material:carbide blade.

5.Workpiece material:AISI1045,200HB.

Fig.2shows the con?guration of a typical BTA drilling tool head.The head nose is designed offset from the axis of the head.308negative rake angle is chips in C shape which must be small enough to go out introduced to strengthen the cutting edge in that area.In order to obtain narrow chips,

the

Journal of Materials Processing Technology 107(2000)222±227

*

Corresponding author.Tel.: 44-113-2833098;fax: 44-113-2833110.

E-mail address :k.cheng@https://www.sodocs.net/doc/8b17748152.html, (K.Cheng).

0924-0136/00/$±see front matter #2000Elsevier Science B.V .All rights reserved.PII:S 0924-0136(00)00684-1

cutting edge is divided into three parts.This depends upon the hole diameter and the material properties of the work-piece.Chip breakers are also required to produce small pieces which can move freely through the very restrictive chip exit mouth and throat.The tool life test was performed with the self-piloting drills with respect to the requirements of the industrial standards(ANSI/ASME B94.55M-1985). The average width of theˉank wear land VB b(cr)is0.3mm that was chosen as the tool life criterion;such a value is common for this type of drilling tools.

The speci?cations of BTA deep hole drills used in the trials are shown in Table1.

3.Chip deformation

3.1.Chip deformation on the three cutting edges Based on the metal cutting theory[5±7],the chip defor-mation can be obtained using the following equations:

g

cos a

sin j cos jàa

(1) where

cot j

t2a t1 àsin a

cos a

(2) t1is the undeformed chip thickness.The mean chip thick-ness t2can be obtained by measuring the length,l,and weight,W,of a piece of chip.So the mean thickness t2is t2

W

r wl

(3)

Using the Eqs.(1)±(3),the chip deformation can be obtained with the data from the machining trials.

In the machining trials,however,it was found that there are different chip deformations on the three cutting edges as shown in Fig.3.The chip deformation cut by the inner edge is the highest,the one by the middle edge is higher,and

the

Fig.1.The deep hole machining trial system.

C.H.Gao et al./Journal of Materials Processing Technology107(2000)222±227223

one by the outer edge is the smallest.The reasons are as follows:

The rake angles on the three cutting edges are different.The right rake angle of the inner edge is à308,as shown in Fig.2.The rake angles of the other two cutting edges are in the range of 0$28.Due to the chip deformation principles [5],the chip deformation cut by the inner edge will be larger than those by other edges,which is con-sistent with the trial results as shown in Fig.4.

The tangential velocities on the three edges are different.Because there are different radii on the three cutting edges,the speed of outer edge is the highest,the one of middle edge is higher,and the one of the inner edge is the smallest.These determine the chip deformation cut by the inner edge being larger than those by others.

The breaker and chip mouth wall.When the chip is removed from the workpiece,the up-curling chip cut by the inner edge will strike the chip mouth except when it strikes the breaker and the workpiece.So

its

Fig.2.A typical BTA drill head used in the drilling trials.

Table 1

Speci?cations of the BTA deep hole drills used in the trials Drill No.D (mm)Cutting edge a Clearance angle F r (mm)W d (mm)H (mm)R (mm)125Outer edge 2836H 6821H 0.10 1.560.39 1.1Middle edge 287826H 0.1 1.650.51 1.1225Outer edge à6834H 881H 0.08 1.300.62 1.0Middle edge à3813H 8856H 0.08 1.440.63 1.0325Outer edge 286H 881H 0.05 1.370.32 1.0Middle edge 2837H 8858H 0.05 1.470.48 1.0425Outer edge 18H 7811H 0.04 1.350.38 1.1Middle edge 2826H 7818H 0.04 1.660.56 1.15

25

Outer edge 1830H 9817H 0.05 1.140.37 1.0Middle edge

185H

9832H

0.06

1.19

0.44

1.0

Fig.3.The chip deformation resulting from the three cutting

edges.

Fig.4.The variation of mean deformation.

224 C.H.Gao et al./Journal of Materials Processing Technology 107(2000)222±227

deformation will increase and be bigger than the other two.

3.2.Effects of the machining conditions

The chip deformation will be affected by the machining conditions.In the drilling trials,the effects of tool rake angle,speed and feed rate were investigated.It was found: When the cutting speed increases,the chip deformation will decrease (as shown in Fig.5).

When the feed rate increases,the chip deformation will increase (as shown in Fig.4).

When the rake increases,the chip deformation will decrease (as shown in Fig.4).These conclusions are very similar to those derived in turning [7].4.Cutting force

The cutting force on the drill consists of the cutting force on the three cutting edges,ˉuid pressure,burnishing force and friction of the pad [8].In the trials,only the axial force was measured.Considering the experimental conditions,the depth of cutting was the same.The axial force was measured by the optical sensor in the systems,as shown in Fig.1.It was found:

When the speed increases,the axial cutting force will decrease,which is shown in Fig.6.

When the feed rate increases,the axial cutting force will increase too as illustrated in Fig.7.

Based on the data from the trials,the empirical equations for the estimation of the axial force in BTA deep hole machining can be expressed as:F x 39044f

0X 95v à0X 15

(4)

The equation is limited to the depth of cut which is 12.5mm for the workpiece material AISI1045steel (HB 200).The empirical equation (4)can be compared with any previously published data as listed in Table 2[8].It can be found from the equation that the axial force is not a linear function of feed.This is probably due to the burnishing effect taking place between the wear pads and the drilled hole surface.The equation is suited for 25mm diameter,AISI1045steel deep drilling.Such an empirical equation can be used to understand the inˉuence of process variables,such as feed rate,f ,and cutting speed,v ,on the mean axial force.5.Deformation and cutting force

In the deep hole machining,the axial force is equal to the resultant force resulting from those on the three cutting edges,ˉuid pressure force,burnishing force and friction.But from the trials it was found that the forces coming from the three cut edges are the main ones.They are much larger than other forces.So only the forces coming from the three cut edges are considered.Based on the metal cutting theory

[5],

Fig.5.The variation of mean deformation with

speed.

Fig.6.The variation of the axial force via the cutting

speed.

Fig.7.The variation of axial force via feed rate.

Table 2

The empirical equation compared to deep hole drilling Investigators Materials Axial force (N)

Griffiths (1982)EN8F am 1912f 1X 06m d

0X 78

Weber (1984)C60F am 33300f m Vd à1X 0100X 026d à0X 137SANDVIK F am 0X 65a p f K cf sin x r

Osman (1985)AISI1020F am 430f 0X 982m d

1X 144

The authors

AISI1045

F x 39044f 0X 95v

à0X 15

C.H.Gao et al./Journal of Materials Processing Technology 107(2000)222±227225

the cutting force comes from the deformation.From the trial data,as shown in Fig.8,it was found that relationship between the axial force in the deep hole drilling and the total deformation of the three cutting edges can be derived as:

F x A

g B (5)where A and B are the constants relevant with the machining

conditions.S g is the total deformation of the three cutting edges.

On the other hand,in two-dimensional cutting,the main force F and the deformation g have the following relationship [5]:F G s t 0f 1X 4g C

(6)

where G s is the shear yield limit,C the constant related to the rake angle,and F x kF

(7)

So Eqs.(6)and (7)yield F x k G s t 0f 1X 4g C

(8)

Using Eq.(8),the axial forces F ox ,F mx ,F ix on the outer edge,middle edge and inner edge,can be expressed as:F ox k G s t 0f 1X 4g o C o (9)F mx k G s t 0f 1X 4g m C m (10)F ix k G s t 0f 1X 4g i C i

(11)So the total axial force on the drill is

F x F ox F mx F ix

k G s t 0f 1X 4g o C o k G s t 0f 1X 4g m C m k G s t 0f 1X 4g i C i 1X 4k G s t 0f g o g m g i z C o C m C i M g N

(12)

where M is the constant related with the machining condi-tions,C o ,C m ,C i ,and N are the constant with the rake.

Eqs.(5)and (12)have similar forms.That illustrates,in

the BTA deep hole drilling process,the axial force is linear with the sum of chip deformation resulting from the three cut edges.6.Wear

In deep hole drilling trials,the data of the wear on the BTA deep hole drill can be obtained through measurement.The BTA deep hole drill life curves can be plotted based on the data as shown in Fig.9.The curves are very similar to the Taylor curve VT n C [5,7].The extent of the low wear region decreases with the increase of the cutting speed.The wear rate rises abruptly when the temperature at the trailing edge of the wear land reaches the thermal softening point of the work material.7.Concluding remarks

In this paper the BTA deep hole drilling machining process was investigated with respect to the chip deforma-tion,cutting forces and wear in the deep hole drilling in particular.It is found that the chip deformation cut by the inner edge is the largest in the three cutting edges of the BTA drill.The chip deformation increases when the feed rate increases,and decreases when the rake and cutting speed increases.The empirical equations of the axial force were developed based on the trial data.The wear curve of the BTA deep drills is very similar to that as shown by the Taylor curve [1].This research laid down a solid basis for further developing an on-line monitoring and control system for the BTA deep hole drilling processes.References

[1]P.K.R.Rao,M.S.Shunmugam,Wear studies in boring trepanning

association drilling,Wear 124(1988)

33±43.

Fig.8.Deformation of the three cutting

edges.

Fig.9.The drill wears curves.

226 C.H.Gao et al./Journal of Materials Processing Technology 107(2000)222±227

[2]J.H.Chin,S.A.Lin,Dynamic modelling and analysis of deep hole

drilling process,in:Proceedings of the Modelling,Simulation and Identi?cation,IASDED,Vancouver,1992,pp.131±134.

[3]S.K.Margos,Measurement and modelling of the cutting force

ˉuctuations,M.Eng.Thesis,Sir George Williams University, Montreal,1973.

[4]V.P.Astakhov,M.O.M.Osman,M.Al-Ata,Statistical design of

experiments in metal cutting-part two:applications,J.Resting Eval.

25(3)(1997)328±336.[5]E.M.Trent,Metal Cutting,3rd Edition,Part of Reed International

PLC,Oxford,1991.

[6]B.Urkovich,Cutting Theory and Chip Morphology,Handbook of

High Speed Machining Technology,Chapman&Hall,New York,1985.

[7]M.C.Shaw,Metal Cutting Principles,Oxford Science Publications,

Oxford,1997.

[8]S.Chandrashekhar,M.O.M.Osman,T.S.Sankar,An experimental

investigation for the stochastic modeling of the resultant force system in BTA deep hole machining,Int.J.Prod.Res.23(4)(1985)657±673.

C.H.Gao et al./Journal of Materials Processing Technology107(2000)222±227227

常用机械加工英语

第1章切削加工基础知识 1.1切削加工概述 切削cutting; 加工machining; 金属切削metal cutting (metal removal); 金属切削工艺metal-removal process; 金属工艺学technology of metals; 机器制造machine-building; 机械加工machining; 冷加工cold machining； 热加工hot working; 工件workpiece; 切屑chip; 常见的加工方法universal machining method; 钻削drilling; 镗削boring; 车削turning； 磨削 grinding; 铣削milling; 刨削planning; 插削slotting ; 锉filing ; 划线lineation; 錾切carving; 锯sawing; 刮削facing; 钻孔boring; 攻丝tap; 1.2零件表面构成及成形方法变形力deforming force; 变形deformation; 几何形状geometrical; 尺寸dimension ; 精度precision; 表面光洁度surface finish; 共轭曲线conjugate curve; 范成法generation method; 轴shaft; 1.3机床的切削运动及切削要素 主运动main movement; 主运动方向direction of main movement; 进给方向direction of feed; 进给运动feed movement; 合成进给运动resultant movement of feed; 合成切削运动resultant movement of cutting; 合成切削运动方向direction of resultant movement of cutting ; 切削速度cutting speed; 传动drive/transmission; 切削用量cutting parameters; 切削速度cutting speed; 切削深度depth of cut; 进给速度feed force; 切削功率cutting power; 1.4金属切削刀具 合金工具钢alloy tool steel;

黄自艺术歌曲钢琴伴奏及艺术成就

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15.特征加工featuremachining

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The machining of materials by cutting is carried out by means of cutting tools. The characteristic feature of all such tools is the wedge-shaped working part, called the tool point. Tools with wedge-shaped points may be used for parting off or for generating shapes. The difference between these two operations is that in parting off the layer separated from the material is usually small and is totally, or for the most Part of it, plastically deformed. The workpiece being machined and the cutting tool must preserve their correct positions during the machining process and must carry out suitable motions in relation to each other. The workpiece and tool are fixed. on a machine, called machine tool, by means of jigs and fixtures. The machine tool also provides the necessary motions of the tool and workpiece. The theory of machining by cutting depends upon several basic sciences which are often interconnected. At present the following machining theories——independent, though interconnected——have been developed: (a) cutting of materials, particularly of metals, in various media; this theory has considerable fundamental importance, (b) machine tool design (kinematics and dynamics), (c) cutting tool design and the study of tool materials, (d) design of machining jigs and fixtures, (e) dimensioning and workshop measurements (workshop, metrology). The theory of metal cutting comprises: —research and scientific induction concerning the phenomena of the cutting process, based on the principles of physics and other basic sciences, —research on important practical characteristics of cutting, comprising: cutting forces and energy, cutting heat and temperature, tool wear, geometrical and physical properties of the surface layer being machined, workpiece accuracy and the kind of waste produced (chip), —preparation of instructions for a scientifically and technically justified choice of machining conditions, in order to optimize the industrial machining process.

英文翻译 Introduction of Machining

山东轻工业学院 中英文翻译 院系名称机械工程学院 学生姓名席福洋 专业班级机械设计制造及其自动化05-3班指导教师宫涛 二○○九年五月十日

Introduction of Machining Have a shape as a processing method, all machining process for the production of the most commonly used and most important method. Machining process is a process generated shape, in this process, Drivers device on the workpiece material to be in the form of chip removal. Although in some occasions, the workpiece under no circumstances, the use of mobile equipment to the processing, however, the majority of the machining is not only supporting the workpiece also supporting tools and equipment to complete. Machining know the process has two aspects. Small group of low-cost production. For casting, forging and machining pressure, every production of a specific shape of the workpiece, even a spare part, almost have to spend the high cost of processing. Welding to rely on the shape of the structure, to a large extent, depend on effective in the form of raw materials. In general, through the use of expensive equipment and without special processing conditions, can be almost any type of raw materials, mechanical processing to convert the raw materials processed into the arbitrary shape of the structure, as long as the external dimensions large enough, it is possible. Because of a production of spare parts, even when the parts and structure of the production batch sizes are suitable for the original casting, Forging or pressure processing to produce, but usually prefer machining. Strict precision and good surface finish, machining the second purpose is the establishment of the high precision and surface finish possible on the basis of. Many parts, if any other means of production belonging to the large-scale production, Well Machining is a low-tolerance and can meet the requirements of small batch production. Besides, many parts on the production and processing of coarse process to improve its general shape of the surface. It is only necessary precision and chooses only the surface machining. For instance, thread, in addition to mechanical processing, almost no other processing method for processing. Another example is the blacksmith pieces keyhole processing, as well as training to be conducted immediately after the mechanical completion of the processing.