Determination of cutting forces in drilling with helical drills using data obtained through turning of circular segments

Abstract

The analysis of cutting forces in machining processes is very important for optimization of cutting parameters, power, costs and the cutting tool geometry. However, because of the high geometrical complexity of helical drills and the drilling process characteristics, analysis of cutting forces and their distribution along the cutting edges and other geometrical elements, are very difficult. Considering that these problems are significantly reduced in the turning process, and also the possibility to correlate data for cutting forces obtained in turning and drilling is given, this study presents a method for the prediction of cutting forces in drilling using results obtained in turning operations. The results for cutting forces in the turning of circular segments, with application of correction factors for variations in the tool geometry, are compared to results obtained during the full drilling of low carbon steels. Aspects of the influence of the cutting tool geometry and cutting parameters on the cutting and thrust forces are also discussed. With the drill model it is possible to indentify the regions with higher mechanical stresses and then geometrical changes on the drill point can be proposed.