CASE 1 (A): SINGLE SPINDLE DRILL BIT

Geometry Modelling for Single Spindle Drill Bit

Fig-1 3D Modelling for Single-Spindle Drill Bit

Figure 3.1 describes the single-spindle K10 drill bit with 6mm diameter and thealuminium plate
having a 10mm thickness. Below drafting figures provides more specification of modelling.
Plate material: Aluminium 5083
Drill material: Aluminum 2024-T4 2
Fig- 2 Properties of Aluminum 2024-T3

Fig:- 3 Properties of Tungsten

Computer-aided design is the use of computer technology for designing and documentation.
CAD software replaces manual drafting with an automated process. Solid works software, which
unlocks the benefits of this powerful 3D design solution for rapid creation of parts, assemblies,
and 2D drawings, was used for the model design is used for designing the assemblies.

Fig-4 Plate drafting

Fig-5 Single Drill Bit drafting

 Fig-6 Single-Spindle Drill Bit Assembly drafting

In figure 6 above one can determine the dimensions of the single drill bit assembly as shown
Meshing
Meshing is the process of dividing the whole component into a certain number of elements.
 Element: An element is a close entity on the surface result of discretization. It is the
basic building block of CFD & FEA analysis
 Node: A node is a coordinate location in space where the degrees of freedom are
defined.
 Fig-7 Single-Spindle Drill Bit Nodes and Elements

After fine mesh was applied, the number of nodes produced was 176336 and element numbers
were 167106. The mesh quality obtained had an average element quality of 0.99531 and
orthogonal quality of 0.99332.

Note: Mesh quality criteria for average element quality and orthogonal quality must be above
0.75 for high accuracy results.

.
Fig-8 Single-Spindle Drill Bit Assembly Element Quality
 Fig-9 Single-Spindle Drill Bit Assembly orthogonal quality
Explicit simulation End time step Calculation :

Time Step Control for Beam and Truss Elements

For the Hughes-Liu beam and truss elements, the time step size is given by:

where L is the length of the element and c is the sound speed:

For the Belytschko beam, the time step size given by the longitudinal sound speed is used, unless
the bending-related time step size given by [Belytschko and Tsay 1982] governs

From the above formulas

E = 2x1011 Pa

L = 4.341x10-2 mm

Density = 2785 Kg / m3

From the above values, we get the end time step as 5x10-4 sec
 Fig-10Step controls for Single drill bit
From Fig 10 we can obtain the input values of of the time step which is calculated earlier and
also the maximum number of cycles of 1x107 which is considered as “infinity” result in Ansys,
this statement signifies that the value of 1x107 is the highest range of cycle in Ansys. This is
important to attain the maximum accuracy for the project.

Meshing

Fig-11 Fine Mesh for side view

Fig-11 Fine Mesh top view

A Body Sizing of 1mm is used on the drill bit and 0.5 mm on the plate is being used. As shown
in Fig-11 hexahedral mesh was used for the plate and tetrahedral mesh was used for the drill bit.

Co-ordinate system

Fig-12 Coordinate system for the Plate

Fig-13 Co-ordinate system for the drill bit

As shown above in Fig-13 the cyclic co-ordinate for the drill bit was used for the application of
the rotation required.Y-direction was chosen for the cyclic rotation with the Z rotational Axis.
Boundary conditions
Boundary Conditions are used in all kinds of numerical simulations. For example, the
temperature can be a boundary condition in thermal analysis. In the case of structural mechanic
studies, boundary conditions are called constraints because they restrict motion of boundaries
(suppress selected degrees of freedom).
An example of a boundary condition would be the application of a force and/or a constraint.

Fig-14 Boundary conditions & Constraint.

Boundary conditions used

 Angular Velocity: An Angular velocity of 2000 rpm was taken for the all drill bits,
rotating in the Y direction with Z rotational Axis. According to the theoretical
calculation, angular acceleration is 720 degree with 5 E-4 sec time step.
 Displacement/Feed rate: Displacement/feed rate of 0.08mm/sec was considered. The
final displacement of the Workpiece plate of 14 mm in5x10-4sec operation.
 Body Interaction: A frictional coefficient of 0.4 and a dynamic coefficient of 0.1 was
taken for the simulation purpose.
Explicit Dynamics settings
 End time step = 5x10-4 sec
 Maximum number of cycles: 1x107
 Note: Explicit dynamics takes a long time to solve due to the solver being based on
explicit dynamics equations that require sufficiently short time steps to track a wave
passing through an element. The speed of sound in the material is dependent on its
modulus and density. The time to traverse an element is size-dependent. For accuracy
higher numbers of cycles are required, hence1x107 cycles were chosen.
 Erosion Controls: It was changed to “On” material failure. These changes allow the
software to handle the particle properties, particle tracks and surface conditioning of the
surface. This provides the exact magnitude of erosion wear.
 Mass Scaling/ Mesh Scaling: Mass scaling was changed to “On” in the software, which
allows the software to variate the mesh sizing, wherever the higher stress is generated
when the material is in contact with the tool for mesh dispersion.
 CASE 2 (A): MULTI SPINDLE DRILL BIT

Geometry Modelling

Fig 15 3D Modeling

Figure 3.9 shows the multi-spindle K10 drill bit of 6mm diameter along with the 10mm thick
aluminum plate. Below, Figure 3.10 provides a 2D engineering drawing of the operation. The
plate dimensions were reduced for faster computational times.

Plate material: Aluminum 2024-T3.

Drill material: Tungsten Carbide.
 Fig-16 Multi Spindle Drill Bit Assembly drafting

Meshing
After the application of fine mesh, the number of nodes produced was 177456 and element
numbers were 170712. The mesh quality obtained had an average element quality of 0.99154 and
an orthogonal quality of 0.98811.

Note: The mesh quality criteria for average element quality and orthogonal quality must be
above 0.75 for high accuracy results.[7]
 Fig-20Fine mesh side view

Fig-21 Fine Mesh top view

An Edge sizing of 1mm and Sweep zone for the Hexahedrons for the drill bit was used.
As shown in Fig 21,the plate having hexahedral mesh and drill tools have tetrahedral mesh
 Fig-17Meshing Details

Fig-18Element Quality

Fig-19Orthogonal Quality

All the values of the meshing quality can be verified as been shown in Fig 18 and Fig 19. These
values justify the higher accuracy attained post-processing in Ansys
Co-ordinate system
A cyclic coordinate system was used for each drill bit for the application of the rotation
required.Y-direction was chosen for the cyclic rotation with a Z rotational Axis.

Boundary conditions

Boundary Conditions are used in all kinds of numerical simulations. For example,the
temperature can be a boundary condition in thermal analysis. In case of structural mechanics
studies boundary conditions are called constraints because they restrict motion of boundaries
(suppress selected degrees of freedom).

The boundary condition is the application of a force and/or constraint.

Fig-22 Coordinate system for the drill bit

 Fig-23 Coordinate system for the Plate

Boundary conditions used

 Angular Velocity: An Angular velocity of 2000 rpm was taken for the all drill bits,
rotating in the Y direction with Z rotational Axis. According to the theoretical calculation
angular acceleration is 720 degrees
 Displacement/Feed rate:Due to an error, a displacement/feed rate of 0.08mm/sec was
considered. The final displacement of the Workpiece plate of 14mm in5x10-4sec
operation. This parameter will be corrected in the following semester along with the
project variations explained in the discussion section.
 Body Interaction: A Frictional Co-efficient of 0.4 and a Dynamic Co-efficient of 0.1 was
taken for simulation purposes.

Explicit Dynamics settings

 End time step = 5x10-4sec
 Maximum num of the cycle : 1x107
o Note: Explicit dynamics takes a long time because the solver is based on explicit
dynamics equations that require time steps short enough to track a wave passing
through an element. The speed of sound in the material depends on its modulus
and density. The time to traverse an element depends on its size. If you have small
elements, that will cause small time steps so we choose only 1x107 time step.
 Erosion Control: It was changed to On Material Failure for our application.
  Mass Scaling/ Mesh Scaling: Mass scaling was changed to “On” in the software, which
allows the software to variate the mesh sizing, wherever the higher stress is generated
when the material is in contact with the tool for mesh dispersion.

4. Preliminary Results and Discussions

CASE 1: SINGLE SPINDLE DRILL BIT

Explicit Simulation Results

Explicit dynamics simulations require a longer time (For full cycle) to obtain accurate results due
to the material failure criteria.

Solution Information Graphs:

Graph-24 Energy conservation with time duration

As shown the Graph 24 the Total Energy, Reference Energy and Work done energy were plotted
Vs the time.
Energy error can indicate problems in the simulation. The default threshold for Energy error is
10%. Any error above this would terminate the solver. The results of a simulation completed
with high energy errors should not be considered accurate. Total Energy increases with time, as
we have fixed the rotation of the drill bit to 720 degrees (2000 rpm), this kinetic energy along
with the friction and operation process, increases the overall energy of the system.

Fig-25 Momentum Summary with time duration

As shown in Graph 25 the Y Momentum of the system is in the cyclic form with reference to
time. Also, the Y impulse means the Y Cyclic rotation is also in cyclic form with time. The
smaller deviation after 2.5x104sec simply denotes the reduce movement of the drill bit due to the
initiation of the drilling process
 Fig-26 Energy Summary with time duration

A shown in Fig 26, the graph of Kinetic Energy of the system was constant and the Contact
Energy increased due to the contact of the drill and workpiece.

Post-processing Explicit Simulation Results

Fig-27Stress on the assembly

 Fig-28 Von –Misses Stress on the workpiece

The maximum stress generated on the Assembly is signified with the Red color and the
Minimum with the Blue color.
Fig-28 shows the Maximum Von-misses stress generated on the Workpiece plate due to the drill
bit interaction with the drill. Maximum von misses generated were 1183.5Mpa which is above
the yield limit of the plate, hence the drilling process takes place in the plate.

Fig-29 Von –Misses Stress on Drill Bit

From above Fig 29 the von–misses stresses present on the Drill Bit had a maximum of
588.45Mpa which is lower than the drill bit Yield Strength, hence the drill bit will not fail In
course of the drilling operation.
 Fig-30 Von –Misses Stress on Drill Bit

The maximum deformation/displacement of the assembly achieved was 72.253mm. The

deformation was highest for the chips coming out of the workpiece

Fig 31 Force reaction/Thrust Force Vs time duration

Shown in the above Fig 31 is the force/reaction force with respect to time duration. The total
thrust force achieved was 8.5x107 N. As the tip of the drill bit penetrates through the workpiece,
the force instantly reduces as shown in the graph. Also, there is a small increase in the force
reaction at the end which denotes the force on the drill bit due to the chips of the plate which is
produced during the drilling operation.

Fig 32 Contact Force Vs Time duration

Maximum contact Force attained as per Fig 32 is8.53x107 N, which is approximately same as the
force reaction mentioned above. This force denotes the force at the contact of the drill bit with
the plate.

Fig 33 Contact Force Vs Time duration

The experimental graph for the single-bit drill process is shown in Fig 33. The similar nature of
the graph was demonstrated showing the sudden drop of the force curve at the end. Hence our
software-driven curve can be justified with the experimental curve achieved

Fig 34Chip Formation in the drilling process

In the above figure 34, the chips coming out of the plate can be seen. Also the accumulation of
the chips during the drilling process can be seen inside the plate.
CASE 2 (A) : MULTI SPINDLE DRILL BIT

Solution Information Graph

Fig 35 Energy conservation with time duration

As shown the Fig 35 the Total Energy, Reference Energy and Work done energy were plotted Vs
the time curve.

Energy error can indicate problems in the simulation. The default threshold for Energy error is
10%. Any error above this would terminate the solver. The results of a simulation completed
with high energy errors should not be considered accurate. Total Energy increases with time, as
we have fixed the rotation of the drill bit to 720 degrees, this kinetic energy along with the
friction and operation process, increases the overall energy of the system.
 Fig 36 Momentum Summary with time duration

As shown in Fig 36 the Y Momentum of the system was in cyclic form with respect to time.
Also, the Y impulse means the Y Cyclic rotation is also in cyclic form with time.

Fig 37 Energy Summary with time duration

A shown the Fig 37 the kinetic energy of the system was constant and the contact Energy
increased due to the contact between the drill and workpiece during the drilling process.

Post-processing Explicit Simulation Results

Fig 38Stress on the assembly

Fig 39 Von –Misses Stress on the workpiece

The maximum stress generated on the Assembly is signified with the Red color and the
Minimum with the Blue color.
Fig-39 shows the Maximum Von-misses stress generated on the Workpiece plate due to the drill
bit interaction with the drill. Maximum von misses generated were 1178.3Mpa which is above
the yield limit of the plate, hence the drilling process takes place in the plate.

Fig 40 Von –Misses Stress on the drill bit

From above Fig 40 the von–misses stresses present on the Drill Bit had a maximum of 492.35
Mpa which is lower than the drill bit Yield Strength, hence the drill bit will not fail In course of
the drilling operation.

Fig-41 Total deformation of the Assembly

As seen in Fig 42 below, the force/reaction force with respect to time duration. The total thrust
force achieved was 8.5x107 N. As the tip of the drill bit penetrates through the workpiece, the
force instantly reduces as shown in the graph. Also, there is a small increase in the force reaction
at the end which denotes the force on the drill bit due to the chips of the plate which is produced
during the drilling operation.

Fig 42 Force reaction / Thrust Force Vs time duration

As shown in the above graph, the highest thrust force achieved was 3.78x108 N.

Fig 43 Contact Force Vs Time duration

Maximum contact Force attained as per Fig 43 is3.78x108N, which is approximately same as the
force reaction mentioned above. This force denotes the force at the contact of the drill bit with
the plate.

Fig 44 Contact Force Vs Time duration

The experimental graph for the single-bit drill process is shown in Fig 44. The similar nature of
the graph was demonstrated showing the sudden drop of the force curve at the end. Hence our
software-driven curve can be justified with the experimental curve achieved

Fig 45Chip Formation in the drilling process

In the above figure 45, the chips coming out of the plate can be seen. Also the accumulation of
the chips during the drilling process can be seen inside the plate.