Influence of Cutting Parameters in Drilling Operations: A Study on Modeling and Simulation using FEM

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill bit is pressed against the work piece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the work piece, cutting off chips from the hole as it is drilled. Drilling operations are conducted on the E Glass epoxy fiber reinforced pieces with 12 mm and 8 mm diameter drills with 118 deg. and 120 deg. point angles with different cutting parameters. The cutting parameters are spindle speed - 1000 rpm and 2500 rpm, Feed - 0.2 mm/rev for 8 mm drill tool and 0.35 mm/rev for 12 mm drill tool. Cutting tool material is HSS. Forces are calculated using theoretical calculations. 3D modeling is done in Creo 2.0 and analysis is done in Ansys. Analysis is performed and the stresses, displacements are compared for three materials Aluminum, Titanium alloy and E Glass Epoxy. By observing the analysis results, the stresses and displacements are less for E Glass Epoxy than Aluminum alloy and Titanium. This book will be especially useful for Mechanical & Metallurgical Engineers.