Coupled Eulerian–Lagrangian simulation and experimental investigation of indexable drilling

Abstract In many industries, indexable insert drills are used to cost effectively produce short holes. However, common problems such as chatter vibrations, premature tool wear and generation of long curly chips that cause poor chip evacuation make optimization the drilling process challenging time-consuming. Therefore, robust predictive models processes desirable support development towards improved designs, enhanced cutting increased productivity. This paper presents 3D finite element simulations AISI4140 workpieces. The Coupled Eulerian–Lagrangian framework is employed, focus predict torque, thrust force, temperature distributions geometries. To reduce computational effort, modelled separately for peripheral central inserts. total force torque predicted by superposing result each insert. Experiments conducted at a constant rotational velocity 2400 rpm feed rates 0.13, 0.16 0.18 mm/rev. While torques in excellent agreement, forces showed discrepancies 12 - 20% experimental measured data. Effects friction modelling on outlined, possible reasons discussed paper. Additionally, indicate tool, local workpiece virtually unaffected rate.