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<p>Micro-cutting operations are crucial in the production of miniaturized products and devices. Among the different micro-cutting processes, micro drilling plays a vital role. Nimonic C-263 superalloy is employed in many applications for its exceptional resistance to thermal fatigue and creep, but the alloy also has machining challenges. So, in this study, finite element simulation was employed to investigate the micro drilling of Nimonic C-263 alloy. The Johnson–Cook material model was considered in the study. Simulations were performed based on the design of experiments for predicting the thrust force and validated with micro drilling experiments. A maximum of 7.69% error was observed between the experiments and simulation, indicating the ability of the finite element model to predict the experimental thrust force. Regarding size effects, a comparative study and insights were reported between the micro drilling and macro drilling of Nimonic alloy. The outcomes of the study can be used to select suitable micro drilling parameter values.</p>

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Analysis of thrust force in micro drilling on Nimonic C-263 alloy using finite element simulation and validated with experiments

  • 期刊论文

  • 发表日期：

    2025年5月10日

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  • S. Geetha,
  • Varatharajan Prasannavenkadesan,
  • S. Selvaraj,
  • M. Mohamed Sidheeq

摘要

Micro-cutting operations are crucial in the production of miniaturized products and devices. Among the different micro-cutting processes, micro drilling plays a vital role. Nimonic C-263 superalloy is employed in many applications for its exceptional resistance to thermal fatigue and creep, but the alloy also has machining challenges. So, in this study, finite element simulation was employed to investigate the micro drilling of Nimonic C-263 alloy. The Johnson–Cook material model was considered in the study. Simulations were performed based on the design of experiments for predicting the thrust force and validated with micro drilling experiments. A maximum of 7.69% error was observed between the experiments and simulation, indicating the ability of the finite element model to predict the experimental thrust force. Regarding size effects, a comparative study and insights were reported between the micro drilling and macro drilling of Nimonic alloy. The outcomes of the study can be used to select suitable micro drilling parameter values.