Finite element investigation and optimization of tool wear in drilling process of difficult-to-cut nickel base superalloy using response surface methodology

Authors

1 Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Isfahan, Iran

2 Department of Mechanical Engineering, Majlesi Branch, Islamic Azad University, Isfahan, Iran

3 Department of Mechanical Engineering, Majlesi Branch, Islamic Azad University, Isfahan, Iran

Abstract

In this research, our attempt is to monitor tool wear through the chip formations, forces, and temperature of edge of drill while drilling in superalloy plate to optimizes effective parameters, which lead to facilitate machining process to, improved tool life, and enhance the productivity. In this study, Inconel718 superalloy material, and cemented coated carbide tool was selected for investigation of tool wear mechanism. Mathematical models were deduced by software Minitab to express the influence of the main cutting variables such as cutting speed, feed rate and tool diameter on tool wear. A wear process model of twist drill is established based on finite element method. The 3D FEA model established here provides a new approach for studying the mechanism of drill wear. The predictive models in this study are believed to produce values of tool wear close to those readings recorded experimentally with a 95% confident interval, verified using ANOVA. The result from the simulation results are agreed with experimental value and predictive value from RSM, proving the ability of the tool wear model in correctly forecasting the tool wear.