Finite Element Analysis and Experimental Investigation of Drilling of Titanium Alloy (Ti6Al4V)

Drilling is a widely used machining process for various components pertaining to industries such as aerospace, automobile etc. Ti6Al4V is very often used for high stressed components like aircraft structure because of its excellent strength to weight ratio. Tool geometry plays a vital role in effective drilling. It is very difficult to develop a modified geometry in order to achieve better hole quality and improved tool life and validating its outcome experimentally is very expensive. The current paper presents the concept of drilling simulation process using commercial finite element software, Abaqus/Explicit. Five major drill bit geometry such as point angle, helix angle, clearance diameter, and web thickness were varied The proposed simulation model for drilling process was based on Eulierian formulation with explicit interaction. The results of simulation were compared with that of experimental drilling. The simulated result has a good correlation with the experimental result. The change in reference point to chisel tip in the simulation yielded better results as compared to when the reference point is taken at top surface of the tool.