Extracting Plowing Forces for Aluminum 6061-T6 Using a Small Number of Drilling Experiments

Authors: Ilige S. Hage, Charbel Y. Seif

Abstract:

Forces measured during cutting operations are generated by the cutting process and include parasitic forces, known as edge forces. A fraction of these measured forces arises from the tertiary cutting zone, such as flank or edge forces. Most machining models are designed for sharp tools; where edge forces represent the portion of the measured forces associated with deviations of the tool from an ideal sharp geometry. Flank forces are challenging to isolate. The most common method involves plotting the force at a constant cutting speed against uncut chip thickness and then extrapolating to zero feed. The resulting positive intercept on the vertical axis is identified as the edge or plowing force. The aim of this research is to identify the effect of tool rake angle and cutting speeds on flank forces and to develop a force model as a function of tool rake angle and cutting speed for predicting plowing forces. Edge forces were identified based on a limited number of drilling experiments using a 10 mm twist drill, where lip edge cutting forces were collected from 2.5 mm pre-cored samples. Cutting lip forces were measured with feed rates varying from 0.04 to 0.64 mm/rev and spindle speeds ranging from 796 to 9868 rpm, at a sampling rate of 200 Hz. By using real-time force measurements as the drill enters the workpiece, this study provides an economical method for analyzing the effect of tool geometry and cutting conditions on generated cutting forces, reducing the number of required experimental setups. As a result, an empirical model predicting parasitic edge forces was developed function of the cutting velocity, tool rake angle, and clearance angle along the lip of the tool, demonstrating strong agreement with edge forces reported in the literature for Aluminum 6061-T6. The model achieved an R2 value of 0.92 and a mean square error of 4%, validating the accuracy of the proposed methodology. The presented methodology leverages variations in machining parameters. This approach contrasts with traditional machining experiments, where the turning process typically serves as the basis for force measurements and each experimental setup is characterized by a single cutting velocity, tool rake angle, and clearance angle.

Keywords: drilling, plowing, edge forces, cutting force, torque