INFLUENCE OF CUTTING PARAMETERS ON THRUST FORCE AND TORQUE IN DRILLING OF ALUMINUM, CAST IRON AND EN28.

Understanding of the fundamentals of metal cutting processes through an experimental study has some limitations. Metal cutting modelling provides an alternative way for better understanding of machining processes under different cutting conditions. Using the capabilities of finite element models, it has recently become possible to deal with complicated conditions in metal cutting. Finite element modelling makes it possible to model several factors that are present during the chip formation including friction at the chip tool interface. The aim of improved understanding of metal cutting is to find ways to have high quality machined surfaces, while minimizing machining time and tooling cost. Friction behaviour at the chip-tool interface is one of the complicated subjects in metal cutting that still needs a lot of work. Several models have been presented in the past with different assumptions. In the current model, the Coulomb friction model, which assumes a constant friction coefficient, is used to model the friction in order to simplify the model. The effect of the constant friction model is considered by analyzing the result for several friction coefficient values and comparing them to the previous work. As simulation tool for the purpose of this study, the FEM software used is DEFORM 3D. DEFORM 3D is a robust simulation tool that uses the FEM to model complex machining process in three dimensions. The simulation results on cutting forces and thrust forces, and shear angle are compared with experimental data in order to indicate the consistency and accuracy of the results when conducting the comparison.