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Influence of Flank Face Structuring on Cooling, Tool Lifetime and Borehole Quality When Drilling Inconel 718: Physical Simulations and Experimental Validation

Authors Daniel Müller, Benjamin Kirsch, Jan C. Aurich

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Author Details

Daniel Müller
  • Institute for Manufacturing Technology and Production Systems, Technische Universität Kaiserslautern, Germany
Benjamin Kirsch
  • Institute for Manufacturing Technology and Production Systems, Technische Universität Kaiserslautern, Germany
Jan C. Aurich
  • Institute for Manufacturing Technology and Production Systems, Technische Universität Kaiserslautern, Germany

Funding

The investigations presented here partly result from the research project IGF 19154N of the German Machine Tool Builders' Association (VDW). It was funded within the program for industrial collective research (IGF) by the Federal Ministry of Economics and Technology (BMWi) via the German Federation of Industrial Research Associations (AiF). This research was also partly funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) – 252408385 – IRTG 2057.

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Daniel Müller, Benjamin Kirsch, and Jan C. Aurich. Influence of Flank Face Structuring on Cooling, Tool Lifetime and Borehole Quality When Drilling Inconel 718: Physical Simulations and Experimental Validation. In 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020). Open Access Series in Informatics (OASIcs), Volume 89, pp. 7:1-7:17, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)
https://doi.org/10.4230/OASIcs.iPMVM.2020.7

Abstract

When drilling difficult-to-cut materials such as Inconel 718, the drills are exposed to high thermomechanical loads. Due to the low thermal conductivity of the workpiece material, a large amount of the generated heat has to be dissipated by the metal working fluid (MWF). However, the cutting zone is located inside the workpiece, which makes it challenging to provide sufficient MWF to the cutting zone. To solve this, drills with internal cooling channels are commonly used. In this work, the influence of differently structured flank faces on cooling efficiency, tool life, process forces and borehole quality is investigated. The influence of the structures on the cooling was investigated by Computational-Fluid-Dynamics (CFD) simulations. These simulations allow a detailed analysis of the flow conditions inside the borehole and showed that the structuring improved flow conditions, especially near the thermally highly loaded main cutting edge. The improved flow conditions resulted in an extension of the tool life by up to 22 % compared to unstructured drills in experimental investigations.

Subject Classification

ACM Subject Classification
  • Applied computing → Physical sciences and engineering
Keywords
  • drilling
  • cooling
  • CFD

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