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<p>The reduction of thermal tool loads in drilling of the difficult-to-machine nickel-based alloy Inconel&#xa0;718 is a crucial aspect in order to optimize the machining operation. Therefore, the process strategy of discontinuous drilling was introduced which is defined by the insertion of cutting interruptions to allow an increased coolant supply. Consequently, the promoted heat transfer into the fluid results in reduced cutting edge temperatures leading to an enhanced process reliability. Measurements of both the thermal loads and the coolant supply during the process are challenging. Well-tailored simulation models can give a deeper understanding of the process and the choice of suitable process parameters. FEM chip formation simulations are an already established possibility to calculate thermomechanical loads acting on the tool as well as the resulting chip form. This usually does not take the influence of the coolant flow into account. Hence, the FEM chip formation simulation is (one-way) coupled with a CFD simulation to consider the influence of the chip geometry. Further, thermal loads arising from chip formation and the friction condition in the secondary shear zones are calculated in a post-processing step and integrated into the CFD simulation to predict the heat evacuation due to the coolant flow. This simulation model is applied to the discontinuous drilling application and various process strategies are discussed and evaluated experimentally.</p>

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The development of a coupled simulation system used to define cutting interruptions for reducing thermal tool loads in drilling of Inconel 718

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年12月29日

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  • Tobias Cyra-Wolf,
  • Michael Fast,
  • Dirk Biermann,
  • Stefan Turek

摘要

The reduction of thermal tool loads in drilling of the difficult-to-machine nickel-based alloy Inconel 718 is a crucial aspect in order to optimize the machining operation. Therefore, the process strategy of discontinuous drilling was introduced which is defined by the insertion of cutting interruptions to allow an increased coolant supply. Consequently, the promoted heat transfer into the fluid results in reduced cutting edge temperatures leading to an enhanced process reliability. Measurements of both the thermal loads and the coolant supply during the process are challenging. Well-tailored simulation models can give a deeper understanding of the process and the choice of suitable process parameters. FEM chip formation simulations are an already established possibility to calculate thermomechanical loads acting on the tool as well as the resulting chip form. This usually does not take the influence of the coolant flow into account. Hence, the FEM chip formation simulation is (one-way) coupled with a CFD simulation to consider the influence of the chip geometry. Further, thermal loads arising from chip formation and the friction condition in the secondary shear zones are calculated in a post-processing step and integrated into the CFD simulation to predict the heat evacuation due to the coolant flow. This simulation model is applied to the discontinuous drilling application and various process strategies are discussed and evaluated experimentally.