Proceedings of the
World Congress on Micro and Nano Manufacturing (WCMNM 2022 )
19–22 September 2022, Lueven, Belgium
doi:10.3850/978-981-18-5180-3_RP68-0074
Finite Element Simulation of Micro-Drilling of a Ni-based Superalloy
1Department of School of Mechanical Engineering, Maharashtra Institute of Technology-wpu, Pune, India
2Department of Mechanical Engineering, Indian Institute of Technology Bhilai, Raipur, India
3Department of Mechanical Engineering, National Institute of Technology Rourkela, Odisha, India
ABSTRACT
In the current work, finite element (FE) simulation was utilised to explore fundamental insights into various microdrilling characteristics of Incoloy 825 using a 0.4 mm drill made up of cemented carbide (WC-Co). The effects of feed on thrust forces, dynamic fluctuation and specific cutting energy were investigated using FE simulation followed by experimental validation. Thrust force along with its dynamic component obtained during experimentation was in close agreement with the results of simulation with a deviation in the range of 7 to 8 %. Evidence from elastic deformation could be clearly observed from the chip formation under 1 μm/rev using FE-simulation. Variation of specific cutting energy determined from simulation and experimental results was a good indication how transition took place from plowing to shear-dominant regimes with increase in undeformed chip thickness.
Keywords: Micro-drilling, MQL, Thrust forces, Dynamic fluctuation, Specific cutting energy.
1Department of School of Mechanical Engineering, Maharashtra Institute of Technology-wpu, Pune, India
2Department of Mechanical Engineering, Indian Institute of Technology Bhilai, Raipur, India
3Department of Mechanical Engineering, National Institute of Technology Rourkela, Odisha, India
ABSTRACT
In the current work, finite element (FE) simulation was utilised to explore fundamental insights into various microdrilling characteristics of Incoloy 825 using a 0.4 mm drill made up of cemented carbide (WC-Co). The effects of feed on thrust forces, dynamic fluctuation and specific cutting energy were investigated using FE simulation followed by experimental validation. Thrust force along with its dynamic component obtained during experimentation was in close agreement with the results of simulation with a deviation in the range of 7 to 8 %. Evidence from elastic deformation could be clearly observed from the chip formation under 1 μm/rev using FE-simulation. Variation of specific cutting energy determined from simulation and experimental results was a good indication how transition took place from plowing to shear-dominant regimes with increase in undeformed chip thickness.
Keywords: Micro-drilling, MQL, Thrust forces, Dynamic fluctuation, Specific cutting energy.
