Mechanistic model for the reaming process with emphasis on process faults

Onik Bhattacharyya, Shiv G. Kapoor, Richard E. Devor

Research output: Contribution to journalArticlepeer-review

Abstract

A mechanistic model is developed to predict the cutting forces for an arbitrary reamer geometry. Inputs to the model include: tool geometry, feed, speed, initial hole geometry, and process faults including parallel offset runout, spindle tilt, their respective locating angles, and tool/hole axis misalignment. Given these input parameters, the model predicts torque, thrust, and radial forces. The cutting edges of the reamer are divided into elements and the elemental forces are determined from a fundamental oblique cutting model. The model is calibrated over a range of feed, speed, and varying tool geometry. Model validation tests were conducted and model predictions match experimental data well. The effects of process faults on cutting forces are examined through model-based studies. It was found that parallel offset runout, spindle tilt, spindle tilt locating angle, and tool/hole axis misalignment have significant effects on the radial forces. These radial forces are shown to be correlated to hole quality.

Original languageEnglish (US)
Pages (from-to)836-846
Number of pages11
JournalInternational Journal of Machine Tools and Manufacture
Volume46
Issue number7-8
DOIs
StatePublished - Jun 2006

Keywords

  • Force model
  • Hole quality
  • Process faults
  • Reaming

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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