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Drilling Force Characterization during Inconel 718 Drilling: A Comparative Study between Numerical and Analytical
Salman Pervaiz1, Wael A Samad1
1Department of Mechanical and Industrial Engineering, Rochester Institute of Technology-Dubai Campus, Dubai P.O. Box 341055, United Arab Emirates.
Materials (Basel, Switzerland)
|September 10, 2021
Summary
This study models cutting forces during Inconel 718 drilling using mechanistic and finite element methods. Results show good agreement between models, aiding prediction of drilling performance and tool wear.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Processes
Background:
- Cutting forces are critical machinability indicators affecting workpiece tolerances and tool wear in drilling.
- Predicting and modeling these forces is essential for optimizing drilling operations.
Purpose of the Study:
- To develop and validate both mechanistic and finite element models for predicting cutting forces in Inconel 718 drilling.
- To compare the accuracy and agreement between the developed models.
Main Methods:
- Developed a finite element (FE) model incorporating strain hardening, strain rate sensitivity, and thermal softening using the power law.
- Developed an analytical mechanistic model considering three drilling stages for a pilot-holed workpiece.
- Validated the FE model against the mechanistic model under various cutting speeds and feed rates.
Main Results:
- Both mechanistic and FE models demonstrated good agreement in predicting cutting forces.
- Discrepancies in average forces for stages II and III were at most 11% and 7%, respectively.
- The models accurately capture material behaviors like strain hardening and thermal softening.
Conclusions:
- The developed models provide a reliable method for predicting cutting forces in Inconel 718 drilling.
- The findings support the use of these models in virtual drilling simulations to analyze process and geometric parameters.
- Accurate force prediction can lead to improved process control, reduced tool wear, and enhanced workpiece quality.
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