Investigations on optimization of the cutting edge of twist drills for the machining of the high temperature resistant nickel-based alloy Inconel 718
Final Report Abstract
The aim of this project was to analyze an adapted flank face design for the drilling of Inconel 718 with regard to tool wear. The nickel-based alloy is used in applications where particularly high heat resistance is required. These include aerospace, the chemical industry and power plant construction. At the same time, these properties also place high demands on the cutting tools, including solid carbide twist drills. The desired modifications to the flank face with grooves or a recess in the flank face are intended to limit wear to the immediate area behind the cutting edge and increase the tool life. In addition, the aim was to improve cooling through the modified tool shape. As part of the first funding phase, the influence of a specifically adjusted flank face relief was systematically analyzed. After recording the resulting mechanical and thermal tool loads and a contact zone analysis with the reference tool, a numerically supported design of the modified tool shape was carried out. In application tests, significant improvements were achieved even with these simple modifications. Especially for process parameter combinations with high productivity, the tool life was more than doubled compared to the reference tool. The aim of the second funding period was to further develop the basic concept of the adapted flank face through the targeted introduction of geometric structures that serve to guide the flow of cooling lubricant in order to cool the cutting edge efficiently. The cooling lubricant flow and the resulting mechanical and thermal interactions on tools with a recess on the flank face were first analyzed in detail in order to evaluate the cooling effect of this modification. Based on this, the targeted design of complex flank face structures was carried out using computational fluid dynamics simulations (CFD). For experimental analysis, the modified tools were realized by grinding the reference tools. In addition to tests to determine the tool life, analyses of the resulting thermal loads were carried out using a two-color pyrometer. The influence on the cooling lubricant flow was investigated using high-speed video analyses with tracer particles in the fluid. The analyses were able to validate the simulatively determined advantages of the complex flank face structures. Overall, the results obtained show considerable advantages of the tool modifications through the targeted improvement of the lubricant supply to the cutting edges. Significantly longer tool life or higher process productivity could be realized, while at the same time the quality of the holes produced was improved.
Publications
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Decreasing Drill Damage. ANSYS ADVANTAGE MAGAZINE 1
Oezkaya, E. & Biermann, D.
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Experimental investigations for a simulative optimization of the cutting edge design of twist drills used in the machining of Inconel 718. Procedia Manufacturing, 14, 8-16.
Biermann, Dirk; Bücker, Milan; Tiffe, Marcel & Özkaya, Ekrem
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Der Rand im Fokus. Werkstatt und Betrieb
Biermann, D.; Bücker, M.; Oezkaya, E. & Haase, M.
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Investigations on the effects of an innovative flank face modification for the drilling of nickel-base alloys. Procedia Manufacturing, 18, 20-26.
Bücker, Milan; Oezkaya, Ekrem; Zimon, Mike & Biermann, Dirk
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A thermomechanical analysis leading to a novel flank face design providing longer tool lives for tools used in the drilling of Inconel 718. The International Journal of Advanced Manufacturing Technology, 102(9-12), 2977-2992.
Oezkaya, Ekrem; Bücker, Milan; Strodick, Simon & Biermann, Dirk
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Neue Methoden zur Entwicklung und Herstellung von Hochleistungswerkzeugen für die Bohrbearbeitung von Inconel 718. Dissertation, TU Dortmund, ISBN: 978-3-8027-8922-9
Bücker, M.
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A New Flank Face Design Leading to an Improved Process Performance when Drilling High-Temperature Nickel-Base Alloys. SSRN Electronic Journal.
Bücker, Milan; Oezkaya, Ekrem; Hensler, Ulf & Biermann, Dirk
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Simulative analyses focused on the changes in cutting fluid supply of twist drills with a modified flank face geometry. International Journal of Mechanical Sciences, 180, 105650.
Oezkaya, Ekrem; Bücker, Milan & Biermann, Dirk
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A modified tool design for the drilling of high-performance aerospace materials. CIRP Annals, 70(1), 83-86.
Iovkov, I.; Bücker, M. & Biermann, D.
