Research Papers: Friction and Wear

Analytical Model of Progression of Flank Wear Land Width in Drilling

[+] Author and Article Information
Ranjan Das

Department of Mechanical Engineering,
Indian Institute of Technology Bombay,
Powai 400 076, Mumbai, India

Suhas S. Joshi

Department of Mechanical Engineering,
Indian Institute of Technology Bombay,
Powai 400 076, Mumbai, India
e-mail: ssjoshi@iitb.ac.in

Harish C. Barshilia

Nanomaterials Research Laboratory,
Surface Engineering Division CSIR-National
Aerospace Laboratories,
Bangalore 560 017, India

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received May 10, 2017; final manuscript received June 3, 2018; published online July 18, 2018. Assoc. Editor: Sinan Muftu.

J. Tribol 141(1), 011601 (Jul 18, 2018) (9 pages) Paper No: TRIB-17-1182; doi: 10.1115/1.4040511 History: Received May 10, 2017; Revised June 03, 2018

In multipoint operations like drilling, cutting velocities and cutting-edge geometries vary along cutting lips so is the rate of progression of flank wear. Analytical evaluation of flank wear land width in the case of complex tools has received a limited attention so far. This work evaluates progression of flank wear in orthogonal machining and adopts it to drilling. An abrasive flank wear has been modeled, wherein, cutting speed determines the rate of abrasion, and the feed rate determines the chip load. The model considers stress distribution along rake surfaces, and temperature-dependent properties of tool and work materials. Assuming that the flank wear follows a typical wear progression as in a pin-on-disk test, the model evaluates cutting forces and the consequent abrasive wear rate for an orthogonal cutting. To adopt it to drilling, variation in cutting velocity and dynamic variation in rake, shear, and friction angles along the length of the cutting lips have been considered. Knowing the wear rate, the length of the worn-out flank (vb) has been evaluated. The model captures progression of flank wear in zones (i), (ii), and (iii) of a typical tool-life plot. It marginally underestimates the wear in the rapid wear region and marginally overestimates it in the steady-state region.

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Fig. 1

(a)–(c) A typical machining process, stress distribution on tool, and tool life plot [13]

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Fig. 2

Approach to the experimental work

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Fig. 3

Approach to modeling of drill flank wear

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Fig. 4

Assumed linear stress distribution over the flank

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Fig. 5

Dynamic geometry of the primary cutting edge [16]

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Fig. 6

Schematic showing flank wear, shaded region during abrasive wear along the tool flank

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Fig. 7

Temperature-dependent variation in yield strength of SS304 [21]

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Fig. 8

Location of flank wear width measurement

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Fig. 9

(a) and (b): Three-dimensional (3D) and two-dimensional plot of Flank wear versus time at four locations along the cutting edge

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Fig. 10

A photograph of the cutting edge showing other mechanicsms of wear

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Fig. 11

(a) and (b) A photograph and schematic diagram of four facet split-point drill: (a) photograph of a four faceted split-point drill and (b) schematic of a four faceted split-point drill giving definition of various featrues of the drill

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Fig. 12

A comparison of flank wear at different locations on drill flank with experimental and analytical model data: (a) x1 = 0.5 mm, (b) x2 = 1.665 mm, (c) x3 = 2.883 mm, and (d) x4 = 4.0 mm



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