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Finite element simulations of cutting force, torque, and temperature in

drilling of Inconel 718

Article  in  Procedia CIRP · July 2019

DOI: 10.1016/j.procir.2019.03.277

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17th CIRP Conference on Modelling of Machining Operations

Finite element17th CIRP Conference on Modelling of Machining Operations

simulations of cutting force, torque, and temperature in
Finite element 28th simulations
CIRP Designdrilling
of of Inconel
cutting
Conference, force,
May 718
2018, torque,
Nantes, Franceand temperature in
Necati Uçakto a, drilling
*,analyze
Adem Çiçek aof Inconel 718 b c
A new methodology the, Ekrem
functionalOezkaya and , Kubilay
physical Aslantas
architecture of
existing products
Necati
Department of Mechanical
fora,Faculty
Uçak
Engieering,
anAdem
*, assembly
Çiçekand
of Engineering , oriented product family identification
a Natural Sciences, Ankara bYıldırım Beyazıt University,06010
Ekrem Oezkaya , Kubilay Aslantas c Ankara, Turkey
a

Institute of Machining Technology, TU Dortmund, Baroper Straße 303, 44227 Dortmund, Germany
b

DepartmentDepartment of Mechanical
Engieering,Engineering, Faculty of Technology,
and NaturalAfyon Kocatepe University, 03200 Afyonkarahisar,
University,06010Turkey
c
a
of Mechanical Faculty of Engineering Sciences, Ankara Yıldırım Beyazıt Ankara, Turkey
*Corresponding author. Tel.:
b
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Institute of Machining
+90-312-324-1555; fax: Technology, TU Dortmund,
+90-312-324-1505. E-mail Baroper Straße 303, 44227 Dortmund, Germany
c
Department of Mechanical Engineering, Faculty of Technology, Afyon Kocatepe University, 03200 Afyonkarahisar, Turkey
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
*Corresponding author. Tel.: +90-312-324-1555; fax: +90-312-324-1505. E-mail

*Abstract
Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

This study presents finite element simulations of cutting force, torque, and temperature in drilling of Inconel 718 superalloy. The FEM simulations
Abstract
were conducted at a cutting speed of 15 m/min and feed of 0.02 mm/rev using an uncoated solid carbide drill. The predicted cutting forces,
Abstract
torques
This studyandpresents
cutting finite
temperatures
element were validated
simulations with theforce,
of cutting experimental results.
torque, and It was observed
temperature in drillingthat a good 718
of Inconel agreement was achieved
superalloy. The FEMbetween the
simulations
predicted
were and measured
conducted force,
at a cutting torque
speed of 15and temperature
m/min and feedvalues.
of 0.02The 3D simulation
mm/rev model thus
using an uncoated solidcan be used
carbide drill.confidently for future
The predicted cuttingplanned
forces,
Ininvestigations
today’sand
torques business environment,
and efficient
cutting the
optimization
temperatures weretrendoftowards
processes
validated more
with andproduct
the tools. variety
experimental and customization
results. It was observed is unbroken.
that a goodDue to this development,
agreement the need the
was achieved between of
agile and reconfigurable
predicted and measuredproduction
force, torquesystems emerged to cope
and temperature withThe
values. various products and
3D simulation product
model thus families. To design
can be used and optimize
confidently production
for future planned
systems
© 2019 asThewell
investigations as to
Authors.
and choose theby
Published
efficient optimal product
Elsevier
optimization of B.V. matches,
processes product analysis methods are needed. Indeed, most of the known methods aim to
and tools.
analyze a product
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one product family
of the on the physical
scientific level. of
committee Different
The 17thproduct families, however,
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on Modelling largely in terms
of Machining of the number and
Operations,
© 2019 The Authors. Published by Elsevier B.V.
nature
in
© the
2019of components.
person
The of the
Authors. This fact
Conference
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Chair
by Dr an
Erdem
Elsevier efficient
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and and
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Dr Tom of appropriate
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Rachid
Peer-review under responsibility of the scientific committee of The 17th CIRP Conference on Modelling of Machining Operationsfamily
Msaoubi.combinations for the production
system. A newunder
Peer-review methodology is proposed
responsibility to analyze
of the scientific existing products
committee in view
of The 17th CIRPofConference
their functional and physical
on Modelling architecture.
of Machining The aim is to cluster
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these
in theproducts
Keywords:
person in the
Finite
of new assembly
element method oriented
Conference (FEM);
Chair Dr product
Inconel
Erdem families
718; forTemperature;
Drilling;
Ozturk and the optimization
Co-chairs Force
Dr Tom of Mcleay
existingandassembly lines Msaoubi.
Dr Rachid and the creation of future reconfigurable
assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
a Keywords:
functionalFinite
analysis is performed.
element method (FEM); Moreover, a hybrid
Inconel 718; functional
Drilling; and Force
Temperature; physical architecture graph (HyFPAG) is the output which depicts the
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
example of a nail-clipper is used to explain the proposed methodology. An MES
Nomenclature industrial case study
minimal on twosize,
element product
mmfamilies of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation Mt of the proposed
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©A, B The
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Nomenclature Authors.parameters,
Published by MPa Elsevier B.V. MES minimal parameters
m, n material element size, mm
C
Peer-review material parameter of the scientific committee of the 28th CIRP
under responsibility Mt Design Conference
torque, Nm 2018.
A, 𝑞𝑞̇ friction dimension
Cc B materialspecific heatparameters,
capacity,MPaJ/kg∙K m,
𝑓𝑓

C material 𝑞𝑞̇ 𝑠𝑠 n material

shear parameters
dimension
CAD computer
Keywords: Assembly;parameter
aided
Design design
method; Family identification
𝑞𝑞̇𝑄𝑄𝑓𝑓̇ friction dimension
heat flux, W/m2
C
2D c specific heat capacity, J/kg∙K
two-dimensional 𝑞𝑞̇R𝑠𝑠 shearradius,
hole dimensionmm
CAD
3D computer aided design
three-dimensional ̇
𝑄𝑄
R 1 heat
outsideflux, W/m2mm
radius,
2D
d two-dimensional
drill diameter, mm
1.3D Introduction R
t the product
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time, s rangemm and characteristics manufactured and/or
dTC three-dimensional
hole diameter for a thermocouple, mm R
T
assembled1 outside
in radius,
temperature,
this °C
system. mmIn this context, the main challenge in
dFc drill
thrustdiameter,
force, N mm
Due holeto diameter
theforce,
fastN t time,
TEXP experimental s temperature, °Conly to cope with single
dFTC cutting fordevelopment
a thermocouple, inmm the domain of modelling and analysis is now not
f
communication and an ongoing trend of digitization and products, temperature,
TSIM simulated a limited °C
temperature,
product °C
range or existing product families,
Fcg thrust force, N
force gradient
digitalization, manufacturing enterprises are facing important TEXP
but m also experimental
melting
to be able to temperature,
temperature,
analyze °C
and to°C
compare products to define
F
ff cutting
feed, force, N
mm/rev
challenges in today’s market environments: a continuing TSIM
new simulated
reference
r product temperature,
temperature,
families. It can be °C
°C
observed that classical existing
F
fzg force
feed per gradient
tooth, mm/tooth
tendency towards reduction of product development times and T
v
productcm melting
cutting
families temperature,
speed,
are m/min
regrouped °C
in function of clients or features.
fh feed, mm/rev
uncut chip thickness, mm
shortened product lifecycles. In addition, there is an increasing T
V
However,
rg reference
velocity
assembly temperature,
gradient
oriented °C families are hardly to find.
product
fz
ht feed transfer
heat per tooth, mm/tooth W/m ∙K
coefficient, 2
demand of customization, being at the same mm time in a global vWC c On thecutting
tungsten
product speed,
carbide m/min
family level, products differ mainly in two
hl uncut
distance chip thickness,
between two mm
thermocouples,
competition with competitors all over 2 the world. This trend, V
z
main g velocity
number gradient
of
characteristics: cutting
(i) theedge
number of components and (ii) the
ht
lsim heat transfertool
simulation coefficient,
length, mm W/m ∙K
which is inducing the development from macro to micro WC of components
type tungsten carbide (e.g. mechanical, electrical, electronical).
l distance between two thermocouples, mm
markets, results in diminished lot sizes due to augmenting z Classical number of cutting edge
methodologies considering mainly single products
lsim simulation tool length, mm
product
2212-8271varieties
© 2019 The(high-volume to low-volume
Authors. Published production) [1].
by Elsevier B.V. or solitary, already existing product families analyze the
To cope with
Peer-review this
under augmenting
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scientific well as to of be
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optimization
Authors. and Co-chairs
Published potentials Dr B.V.
by Elsevier Tom
in Mcleay and Dr Rachid
the existing causes Msaoubi.difficulties regarding an efficient definition and
Peer-review under
production system,responsibility of the scientific
it is important to havecommittee
a preciseofknowledge
The 17th CIRP Conference
comparison on Modelling of Machining
of different productOperations,
families.in theAddressing
person of the this
Conference Chair Dr Erdem Ozturk and Co-chairs Dr Tom Mcleay and Dr Rachid Msaoubi.
2212-8271 © 2019 The Authors. Published by Elsevier B.V.
Peer-review
2212-8271 under
© 2017 responsibility
The of the by
Authors. Published scientific
Elseviercommittee
B.V. of The 17th CIRP Conference on Modelling of Machining Operations
10.1016/j.procir.2019.03.277
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
48 Necati Uçak et al. / Procedia CIRP 82 (2019) 47–52
2 Necati Uçak et al. / Procedia CIRP 00 (2019) 000–000
Greek Symbols
𝛼𝛼 clearance angle, degree
𝛼𝛼𝐴𝐴𝐴𝐴𝐴𝐴 convection coefficient air flow, W/m2∙K
𝛼𝛼𝐴𝐴𝐴𝐴𝐴𝐴_𝑁𝑁𝑁𝑁𝑁𝑁 convection coefficient air non-flow, W/m2∙K
𝛾𝛾𝑛𝑛 rake angle, degree
Φ point angle, degree
𝜃𝜃𝑛𝑛 friction angle, degree
𝛽𝛽0 wedge angle, degree
𝜎𝜎 equivalent stress, 1/s
𝜀𝜀 plastic strain
𝜀𝜀̇ strain rate, 1/s
𝜀𝜀̇0 reference strain rate, 1/s
𝜌𝜌 density, kg/m3
𝜏𝜏 shear flow stress, Mpa
𝜑𝜑 shear angle, degree
Introduction
Nowadays, modelling and simulation of metal cutting
processes, employed in order to minimize expensive and time-
consuming experimental studies, have become increasingly
popular due to the enhanced computational capacity of modern
computers. In comparison to analytical models, they provide
more exhaustive and accurate predictions about the effects of
cutting conditions on the machining performance, such as
cutting forces, temperatures, tool wear, residual stresses, and
chip and burr formations. In addition, some valuable
information, such as the stresses on the cutting tool which is
difficult to obtain experimentally can be simply predicted with
the finite element analysis [1]. However, the validity of
assumptions and boundary conditions in numerical simulations
have not been at a desired level, due to poor representations of
real machining processes [2]. In numerical simulations of
metal-cutting processes, there are two main issues. The first
one is the material model, which must adequately represent
deformation behavior during high strain rate loading, as well as
low strain rate loading under a range of temperatures, and
account for hardening and softening processes. The second one
is related to the modelling and numerical realization of large
configuration changes. The numerical simulation of machining
processes involves large strains and angular distortions,
multiple contacts and self-contact, generation of new
boundaries, and fracture with multiple cracks and
defragmentation. All of the above are difficult to handle using
standard finite-element methods (FEM) [3]. Currently, many
research works are carried out to overcome these issues in the
numerical simulation of cutting processes. Although there are
a lot of literature studies conducted concerning the usage of
FEM to predict the performance characteristics in machining
of a wide range of workpiece materials [4–7], a simple valid
model to predict performance characteristics in the drilling of
Inconel 718 [8, 9] superalloy using FEM is not adequately
addressed in the literature. Therefore, this study focuses on
numerical simulations of thrust force, torque, and temperature
in drilling of Inconel 718 superalloy using solid carbide drills.
The software Deform 3D was employed to obtain numerical
results. In addition, to verify obtained maximum cutting
temperature and thrust force results, a thermal analysis with the
aid of the software ANSYS and a 2D finite element model
analysis (as in [1] and [2]) using Deform 2D were carried out.
Finally, the numerical results from FEM simulations were
validated with experimental ones.
1.1. 3D FEM chip formation simulation
While the chip formation is predominantly modelled two-
dimensionally in an orthogonal section with many model
simplifications by means of FEM, the 3D analysis, especially
in oblique cutting, offers more realistic results [10]. In addition,
the complex tool geometry and rotation effects can be
completely visualized and the thermo-mechanical loads
determined accordingly [11]. The 3D FEM chip formation
simulation is particularly challenging for very small and
complex geometries. In addition to the consideration of many
boundary conditions due to plastic deformation with high strain
rates and high temperatures in the already very small cutting
zone, it has to be considered that the minimum element edge
length must be at least three times smaller than the chip
thickness [12]. The choice of the element size and orientation
also has a large influence on the simulation results, e.g. a
correct prediction of the cutting forces and chip geometry [13].
In addition, it is important for the investigation of tribological
stresses in the cutting zone that the specific cutting shape of the
cutting edge is positioned exactly on the bore ground of the
workpiece in an appropriate engagement situation, which
results in both a symmetrical and asymmetrical profile [14]. In
this way, a realistic starting condition could be generated,
benefiting the overall simulation performance.
1.2. Temperature prediction
Temperature and heat distribution are of great importance
in machining processes, as this factor has a strong influence on
tool life. The highest temperatures can be expected between the
chip and the tool, as the degree of deformation in the flow zone
on the underside of the chip is considerably higher than in the
shear zone. Temperature development and heat distribution are
influenced by the machining process, the used workpiece
material and tool material, cutting conditions, tool wear and
cutting fluid. The tool temperature and the heat flux density can
often not be measured directly, so that different inverse
solution methods are used to determine these variables [15].
However, while analytical methods suffer from the greatly
simplified assumptions, the two-dimensional FEM has been
used successfully, i.e. with sufficient accuracy [16]. However,
the transition to three-dimensional analysis is still relatively
problematic due to the high modelling effort, the lack of basic
input data and the corresponding computing times.
2. Experimental setup and procedure
The tests were conducted at a cutting speed of vc = 15 m/min
and feed of f = 0.02 mm/rev using an uncoated solid carbide
(WC) drill. Uncoated WC twist drills with a diameter of
d = 5 mm, helix angle of 30°, and point angle of 140 ° were
used in this study. In the tests, the hot rolled, descaled, and
annealed Inconel 718 (90.5 HRB) plates with dimensions of
100 mm×80 mm×15 mm were used as the workpiece samples.
For the experimental investigations, a Kistler 9272 4-
component dynamometer and Kistler Type 5070A01100
multichannel charge amplifier were used to measure thrust
 Necati Uçak et al. / Procedia CIRP 82 (2019) 47–52 49
Necati Uçak et al. / Procedia CIRP 00 (2019) 000–000 3

force and torque values. Data measured by the dynamometer

was converted to numerical values through the software
DynoWare. Mean of thrust force and torque values measured
from three drilling operations were calculated, resulting in final
thrust force and torque values. K type (NiCr-Ni) thermocouples
with a diameter of 1 mm, which can measure temperatures in
the range between -200 °C and 1200 °C, were employed for the
measurement of cutting temperatures. In order to prevent
deformation during the tests and to get more accurate and
reliable measurements [17], the thermocouples were insulated
with Inconel 600 protective tubes. The temperature recordings
were monitored on an Elimko data logger (E-PR-110). The five
Fig. 2: Real tool and CAD model of a carbide twist drill.
thermocouples defined as T1 to T5 (Figure 1) were positioned at
an approximate distance of 0.1 mm from the drilled hole wall
to measure the temperatures generated during the drilling
process. The entrance thermocouple (T1) was located at a
distance of 1.75 mm from hole entrance and the others were
arranged at 3 mm intervals through the workpiece thickness. A
schematic representation of the experimental setup is given in
Figure 1.

Fig. 3: Modelling of the geometrical kinematic imprint

For the description of the deformation and failure behavior,

the thermoviscous-plastic material model of Johnson & Cook
was used [18]. The equivalent stress 𝜎𝜎 is calculated as follows:
𝜀𝜀̇ 𝑇𝑇 − 𝑇𝑇𝑟𝑟 𝑚𝑚
𝜎𝜎 = (𝐴𝐴 + 𝐵𝐵𝜀𝜀 𝑛𝑛 ) [1 + 𝐶𝐶 ln ( )] [1 − ( ) ] (1)
𝜀𝜀̇0 𝑇𝑇𝑚𝑚 − 𝑇𝑇𝑟𝑟

Here, 𝜀𝜀 is the plastic strain, 𝜀𝜀̇ is the strain rate, 𝜀𝜀̇0 the
reference strain rate, T the temperature, Tr the reference
temperature and Tm the melting temperature. The material
parameters A, B, C, n and m are listed in Table 1. The yield
strength of the material (A) is used according to certificate
value of the workpiece material [17]. In addition, the hardening
Fig. 1: Experimental setup modulus of the material (B) was studied in simulations until to
achieve a good agreement with experimental results. The other
3. Modelling and simulation material constants were adopted from the study reported by
Uhlmann et al. [19] for annealed Inconel 718 workpiece
3.1. Workpiece and cutting tool geometries material. All other simulation constraints are listed in Table 2.

To execute 3D simulation, the drilling tool geometry was Table 1. Johnson & Cook model parameters of Inconel 718
examined using a ZOLLER Genius 3, GFM MikroCAD, and A in MPa B in MPa n C 𝜺𝜺̇ in 1/s m Tr in °C Tm in °C
Nanovea optical profilometer, so that the twist drill could be ͵͸ͺǤͳͺ ͸ͲͲ ͲǤ͸ͷ ͲǤͲͳ͹ ͲǤͲͲͳ ͳǤ͵ ʹͲ ͳʹͻ͹
modelled in a computer aided design (CAD) environment.
Figure 2 indicates the main parts of the twist drill and their Table 2. Boundary conditions for modelling and simulation
properties on both real tool and CAD model. A precise Tool Workpiece
kinematic imprint of the engagement position for the 3D FEM Drill Outside
d = 5 mm R1 = 2.75 mm
simulation using mathematical and simulation methods diameter radius
elaborated in [14] was created (Figure 3). Since the feed of Drill type helical-fluted Hole radius R = 2.50 mm
f = 0.02 mm/rev corresponds to a feed per tooth of only fz = Simulation
lsim = 5 mm Material Inconel 718
tool length
0.01 mm/rev, the FEM modelling and meshing of the already
Material Johnson and
very complex micro-tool geometry is associated with Point angle 𝛷𝛷 = 140°
model Cook
additional high demands. The minimum element size (MES) Friction;
Material WC Shear = 0.45
must be at least three times smaller than the chip thickness for hybrid
the chip formation simulation and in this case corresponds to a Cutting Heat transfer 2
vc = 15 m/min ht = 45 W/m ∙K
speed coefficient
very fine local mesh of MES = 0.0035–0.0040 mm (Figure 4). Elements 200,000 Elements 490,000
Object type rigid Object type plastic
 50 Necati Uçak et al. / Procedia CIRP 82 (2019) 47–52
4 Necati Uçak et al. / Procedia CIRP 00 (2019) 000–000

calculated force of the 2D simulation was compared to the 3D

results. Overall, there is a good agreement between the
experimental and simulation results, which confirms the good
3D model quality.

Fig. 4: Meshing conditions for the 3D simulation

In addition to 3D, 2D modelling in an orthogonal section

was also performed for calibration of material model and
extended validation purposes. In order to transform a drilling
operation into a 2D process, the drilling process was
subdivided into a number of orthogonal cuts along the cutting
edge as in the study of Biermann et al. [20]. 2D simulations
Fig. 5: Properties of the 2D simulation
were conducted with a variation of cutting speed and cutting-
edge micro geometry along six different points of the cutting
edge, due to the tool diameter dependency of cutting speed and
wedge angle 𝛽𝛽0 . In addition, the rake angle 𝛾𝛾𝑛𝑛 was specified by
the wedge angle 𝛽𝛽0 and the clearance angle 𝛼𝛼 according to
locations of orthogonal cuts. The model consists of two
separately modeled solids, the workpiece and the cutting edge
of the tool. In local fine meshing, the MES is assumed to be ten
times smaller than the chip thickness. This ensures that enough
elements reliably simulate the low chip thickness. Figure 5
shows the kinematic conditions with the properties of
workpiece and tool. After 2D simulations were performed, the
obtained cutting forces were added and converted to thrust
force using following equation:
𝐹𝐹𝑐𝑐 = 𝑧𝑧 × 𝐹𝐹𝑓𝑓 × 𝑠𝑠𝑠𝑠𝑠𝑠(Φ/2) (2)
Here 𝐹𝐹𝑐𝑐 is the thrust force experimentally obtained as
Fig. 6. Validation of the simulation results with experimental data
358.62 N, 𝐹𝐹𝑓𝑓 is the 2D cutting force, z is the number of cutting
edges, and Φ is the point angle. 2D simulations were continued
until the cutting forces reached the steady-state condition. 3.3. Simulation results of temperature
However, since the chisel edge has no cutting effect and is
responsible for penetration into the workpiece material, a The results of the 3D simulation show an increase in chip
continuous increase in cutting force was observed during the root temperatures and a particularly hot zone at the tip of the
simulation. Therefore, the cutting force at chisel edge (at Ø 0.1 tool with a maximum calculated temperature of
mm) was determined considering the penetration time TSIM_3D ≈ 500 °C (Figure 7). The resulting temperature
dependent cutting force result (at 0.00118 s). distribution in the contact zone is clearly visible and shows that
the tool is exposed to a high thermal load.
3.2. Simulation results of force and torque

The results of the 3D simulation were averaged and

compared to the experimentally measured values, whereby the
thrust force 𝐹𝐹𝑐𝑐 and torque 𝑀𝑀𝑡𝑡 were evaluated (Figure 6). The
curves show that after a certain time a plateau is formed, i.e.
the values do not increase any further, so that the validation
takes place in this time window. 750 simulation steps thereby
Fig. 7. Results of the 3D simulated temperature
correspond to a time interval of Δt = 0.0079 s. In addition, the
 Necati Uçak et al. / Procedia CIRP 82 (2019) 47–52
Necati Uçak et al. / Procedia CIRP 00 (2019) 000–000
In the 3D model, the temperature is determined inversely,
taking into account the convection coefficients of the air non-
flow 𝛼𝛼𝐴𝐴𝐴𝐴𝐴𝐴 𝑁𝑁𝑁𝑁𝑁𝑁 on the worpiece surface and that of the air flow
𝛼𝛼𝐴𝐴𝐴𝐴𝐴𝐴 on the hole surface (Figure 8). The heat flux 𝑄𝑄̇ (Eq. 2) is
varied until the simulated maximum temperatures TSIM at the
respective thermocouple positions from T1 to T5, correspond to
the experimentally obtained values TEXP. In conclusion, the
hole wall temperature TWALL could be calculated.
𝑄𝑄̇ = ℎ𝑡𝑡 (𝑇𝑇𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 − 𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆 )
Here, ht is the heat transfer coefficient. The heat balance
equation in all three spatial directions (x, y, z) can be defined
as follows:
𝜕𝜕𝜕𝜕
𝑄𝑄̇𝑥𝑥 + 𝑄𝑄̇𝑦𝑦 + 𝑄𝑄̇𝑧𝑧 + 𝑄𝑄̇𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 + 𝑄𝑄̇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 𝜌𝜌𝐶𝐶𝑐𝑐 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑.
𝜕𝜕𝜕𝜕
Here, 𝜌𝜌 is the density and Cc is the specific heat capacity
and t is the time. The heat flux can be described with:
𝑄𝑄̇ = 𝑞𝑞̇ 𝑠𝑠 + 𝑞𝑞̇ 𝑓𝑓 .
The heat production rate per control volume unit is
dependent on the heat generated and arises inter alia by the
velocity gradient Vg and force gradient Fg along the shear
dimension 𝑞𝑞̇ 𝑠𝑠 and friction dimension 𝑞𝑞̇ 𝑓𝑓 [21].
𝜏𝜏ℎ𝑣𝑣𝑐𝑐 𝑐𝑐𝑐𝑐𝑐𝑐(𝛾𝛾𝑛𝑛 )
𝑞𝑞̇ 𝑠𝑠 = 𝑉𝑉𝑠𝑠 𝐹𝐹𝑠𝑠 =
𝑠𝑠𝑠𝑠𝑠𝑠(𝛾𝛾𝑛𝑛 )𝑐𝑐𝑐𝑐𝑐𝑐(𝜑𝜑 − 𝛾𝛾𝑛𝑛 )
𝜏𝜏ℎ𝑣𝑣𝑐𝑐 𝑠𝑠𝑠𝑠𝑠𝑠(𝜑𝜑)
𝑞𝑞̇ 𝑓𝑓 = 𝑉𝑉𝑓𝑓 𝐹𝐹𝑓𝑓 =
𝑐𝑐𝑐𝑐𝑐𝑐(𝜑𝜑 + 𝜃𝜃𝑛𝑛 − 𝛾𝛾𝑛𝑛 )𝑠𝑠𝑠𝑠𝑠𝑠(𝜑𝜑 − 𝛾𝛾𝑛𝑛 )
Here ℎ is the uncut chip thickness, 𝜏𝜏 the shear flow stress,
𝛾𝛾𝑛𝑛 the normal rake angle, 𝜃𝜃𝑛𝑛 the normal friction angle and 𝜑𝜑
the normal shear angle. The calculated temperatures reached a
very good agreement with a marginal average difference of
0.1 % compared to the experimental values (Figure 8).
Fig. 8. Inverse determination of temperatures and validation
51
5
Starting from the experimentally determined and simulated
temperatures at the thermocouple positions T1 to T5, the
according five calculated heat flux were used to simulate the
temperature distributions in the contact zone between
workpiece and tool, as well as on the hole wall. It was observed
that the temperature reaches a plateau at a maximum
temperature of TWALL = 453.1 °C in the immediate vicinity of
the cutting edge close to the position T5 (Figure 9).
(3)
(4)
(5)
(6)
Fig. 9. Determination of the tool temperature with simulation
(7) Compared to the results of the maximum temperature from
the 3D simulation (DEFORM 3D) of TSIM_3D ≈ 500 °C, the
maximum temperature of the 3D simulation (ANSYS) of
TWALL = 453.1 °C shows a very good agreement. Figure 10
illustrates this context. The high 3D model quality has been
proven by the experimental and simulation validation, so that
this model can be used confidently for future investigations and
optimizations of the process and the tool.
Fig. 10. Comparison of the simulated maximum temperature of position T5
4. Conclusions
In this paper, the performance of an uncoated WC twist drill
with a diameter of d = 5 mm was investigated experimentally
and numerically during machining of Inconel 718. The tests
were carried out under dry condition. During the tests, thrust
force, torque, and temperature measurements were performed.
For the implementation of the thermal 3D modelling and
simulation, a precise geometric kinematic imprint within the
workpiece was realized. This overcomes superimpositions of
cutting speed and axial feed, avoids crushing processes without
 52 Necati Uçak et al. / Procedia CIRP 82 (2019) 47–52
6 Necati Uçak et al. / Procedia CIRP 00 (2019) 000–000
material separation and saves valuable computing time. After
the import into the FEM simulation environment DEFORM
3D, the boundary conditions were defined and the very small
and complex geometry could be precisely meshed. In addition,
a 2D simulation model was created for determination of precise
material model and extended validation purposes. The 3D
simulation results of the mechanical load were validated with
both the experimental and the calculated 2D results. Since
Inconel 718 is a high strength material, plateaus of force and
torque values were reached almost immediately after the tool
engagement. However, due to the poor thermal conductivity of
Inconel 718, a much longer simulation time was required to
reach to a stable temperature. The steady state temperature
value was reached in 3D simulation. After the approximation
of the temperatures at the thermocouple positions T1 to T5, the
heat flux could be determined inversely. In this way, the 3D
simulation was used to numerically calculate the temperature
and heat distribution in the workpiece and tool. The maximum
temperature of the 3D simulation of TSIM_3D = 500 °C
corresponds very well to the maximum calculated temperature
of the 3D simulation of TWALL = 453.1 °C, so that a valid
approach and a high model quality were achieved. The new and
novel 3D simulation model presented here can therefore be
used confidently for further future investigations and efficient
optimization tasks.
Acknowledgements
This work was financially supported by AYBU Scientific
Research Projects Commission (Project no: 3578) and Afyon
Kocatepe University Scientific Research Projects Commission
(Project No: 18.KARIYER.247).
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