The effect of runout and its relation to the radial forces and drill deflection is discussed. The need for a mechanistic model to predict the effects of drill geometry and drilling forces on the hole quality is the chief motivation for this study. Develop a model for the dynamic drill deflections that accounts for changing chip area using the deflection model developed by R. Sriram 2. Conduct experiments to better understand the effect of drill geometry along with process parameters on the hole quality such as cylindricity, location and size errors and hole straightness 3. Develop models to predict hole quality such as cylindricity, location and size errors and hole straightness based on drill geometry and process parameters 4.
Experiments are underway to perform drilling operation and measure the hole quality parameters.
Experiment setup includes drilling various workpiece materials such as 1018 Steel, Aluminum alloy 319, Gray cast iron with different drill geometries which include drill diameters and drill heights. The drilling forces and moments along with the hole quality parameters are to be measured 2. From these experiments, a data base will be generated and used to obtain a correlation between the drilling process and hole quality 3. Get a dynamic drill deflection model to predict the drilling forces and moments 4. The mechanistic model for the complete three dimensional force system for the conical and arbitrary drill point geometry has been developed by Vivek Chandrasekharan.