Dynamics of Initial Penetration in Drilling: Part 1—Mechanistic Model for Dynamic Forces

Abstract

This two-part paper is aimed at developing a theoretical and numerical simulation basis for initial penetration phenomena that profoundly influence hole tolerances and shape. In Part 1, dynamic force models are developed followed by models of the drill’s dynamic behavior in Part 2. Next, these models are combined and used to predict initial penetration behavior and hole shape. A comparison of simulated and experimental results concludes Part 2. In this part, by considering the effects of drill grinding errors and drill deflections, dynamic cutting chip thickness models are developed which, in combination with workpiece surface inclination effects, allow the formulation of expressions for the dynamic chip thickness and cutting chip cross-sectional area. By using these quantities to replace their static counterparts, static drilling force models are extended to facilitate the prediction of dynamic cutting forces. Separate thrust, torque, and radial force models for the major cutting edges, secondary cutting edge, and for the indentation zone are formulated. The effects of drill installation errors on the radial cutting forces acting on the chisel edge and the major cutting edges are also included.