Axial cutting force in drilling operation

Abstract: Metal cutting has been part of industrial development since the iron age. Since then, it has changed shapes and criteria, but efficiency in metal cutting has been one of the biggest goals in the industrial world for just as long. To have maximum efficiency requires some level of process behavior prediction, which inspired the degree project. The project was conducted in collaboration with Lund University and Seco as an academic degree project for the university and as a practical tool for Seco. The project started with a literature review, where existing models in predicting axial cutting force in drilling operations were thoroughly studied and analyzed. The result of the literature review was one chosen model for further tests and modifications. The chosen model was used to predict the axial cutting force for chosen tool diameters and feed machining SS2541 in the material group P5. Experimental tests were performed to test the model. They showed that the prediction was not a perfect fit, which led to mathematical tests where different solver-based constants were added to the model to provide the minimum possible error percentage between the measured and modeled axial cutting forces. During this phase of the project, a pattern was detected where the model underestimated the axial cutting force for smaller diameters. The results are presented in performance order where the correlation between diameter, feed, measured and modeled axial cutting force is both visualized in graphs and described in the report. Furthermore, a chapter with a suggestion for future studies has been added to optimize the model further.