Title: Chamfer drill geometric parameters optimisation by finite element simulation and experimental analysis

Authors: Julius Caesar Puoza; Sampson Takyi Appiah; Tainyao Zhang; Bernard Aboagye

Addresses: Department of Mechanical Engineering, Sunyani Technical University, P.O. Box 206, Sunyani, Ghana ' Department of Mathematics and Statistics, University of Energy and Natural Resource, P.O. Box 241, Sunyani, Ghana ' School of Mechanical Engineering, Jiangsu University, 301 XueFu Road, 212013 Zhenjiang, China ' Department of Mechanical Engineering, Sunyani Technical University, P.O. Box 206, Sunyani, Ghana

Abstract: In this research paper, finite element models for drilling and milling were built respectively for a new chamfer drill tool and simulation results obtained for the best combination of geometric parameters. An orthogonal milling test experiment was conducted using a CNC vertical milling machine to obtain the cutting force and surface roughness. The rake angle of 15°, relief angle of 4°, base circle of 60% and helix angle of 0° produced the minimum milling force during the simulation test. A comparison of the simulated results and the experimental results gave an error limit of 4% indicating that the accuracy and reliability of the simulation are better. The experimental results showed that the chamfer depth of 1 mm, cutting speed of 120 m/min and feed of 0.1 mm per tooth exhibited the best combination of cutting parameters in terms of low cutting force and surface roughness.

Keywords: chamfer drill; simulation; optimisation; surface roughness; cutting force.

DOI: 10.1504/IJMMM.2020.109852

International Journal of Machining and Machinability of Materials, 2020 Vol.22 No.5, pp.406 - 429

Received: 17 Aug 2019
Accepted: 15 Jan 2020
Published online: 28 Sep 2020 *

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