Experimental and analytical analyses of the cutting process in the deep hole drilling with BTA (Boring Trepanning Association) system
Open Access
- 1 January 2013
- journal article
- research article
- Published by EDP Sciences in Mechanics & Industry
- Vol. 14 (6), 413-429
- https://doi.org/10.1051/meca/2013087
Abstract
This paper deals with analysis of the cutting process, on a macro and micro scale, in the deep hole drilling with BTA system. An experimental procedure is developed to highlight the impact of cutting speed and feed rate on the cutting process when machining the 18MND5 steel. Parameters based on dimensional characteristics of chips are introduced to quantify the morphology of chips generated by central, intermediate and external inserts of the complex BTA drilling tool. From observation of the chips morphology (flat, curved and spiral) and the measurement of the chips width, the provenance of each chip with respect to cutting inserts is identified. Then, the Chip Compression Ratio is evaluated for each cutting condition, indicating the amount of plastic strain in chips. Thanks to the introduction of a new parameter, denoted as Chip Fragmentation Ratio, it is found that the cutting speed has a little influence, compared to the feed rate, on the chips size. Based on this quantitative analysis, the optimal range of cutting conditions for the BTA deep hole drilling is discussed. It is mentioned that although increasing the feed rate promotes the chips fragmentation and increases the material removal rate (increasing productivity), an upper limit is to determine to prevent excessive flank wear. Also, the cutting speed should be limited to avoid excessive crater wear.Keywords
This publication has 41 references indexed in Scilit:
- Analysis of a new Segmentation Intensity Ratio “SIR” to characterize the chip segmentation process in machining ductile metalsInternational Journal of Machine Tools and Manufacture, 2011
- Characteristics of cutting forces and chip formation in machining of titanium alloysInternational Journal of Machine Tools and Manufacture, 2009
- A numerical simulator to predict the dynamical behavior of the self-vibratory drilling headInternational Journal of Machine Tools and Manufacture, 2008
- Chip thickening in deep-hole drillingInternational Journal of Machine Tools and Manufacture, 2006
- Continuous chip formation in drillingInternational Journal of Machine Tools and Manufacture, 2005
- Effects of support misalignments in deep-hole drill shafts on hole straightnessInternational Journal of Machine Tools and Manufacture, 2001
- Observations on chip formation and acoustic emission in machining Ti–6Al–4V alloyInternational Journal of Machine Tools and Manufacture, 2001
- An analytical evaluation of the cutting forces in self-piloting drilling using the model of shear zone with parallel boundaries. Part 2: ApplicationInternational Journal of Machine Tools and Manufacture, 1996
- An analytical evaluation of the cutting forces in self-piloting drilling using the model of shear zone with parallel boundaries. Part 1: TheoryInternational Journal of Machine Tools and Manufacture, 1996
- Study on Deep-Hole-Drilling with Solid-Boring Tools : The Effect of Tool Materials on the Cutting PerformanceBulletin of JSME, 1978