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Mathematical Problems in Engineering
Volume 2014, Article ID 543298, 11 pages
http://dx.doi.org/10.1155/2014/543298
Research Article

A Mathematical Modeling to Predict the Cutting Forces in Microdrilling

1Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing 100081, China
2Hebei United University, Tangshan 063009, China

Received 4 June 2014; Revised 18 July 2014; Accepted 19 July 2014; Published 6 August 2014

Academic Editor: Zhen-Lai Han

Copyright © 2014 Haoqiang Zhang et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Abstract

In microdrilling, because of lower feed, the microdrill cutting edge radius is comparable to the chip thickness. The cutting edges therefore should be regarded as rounded edges, which results in a more complex cutting mechanism. Because of this, the macrodrilling thrust modeling is not suitable for microdrilling. In this paper, a mathematical modeling to predict microdrilling thrust is developed, and the geometric characteristics of microdrill were considered in force models. The thrust is modeled in three parts: major cutting edges, secondary cutting edge, and indentation zone. Based on slip-line field theory, the major cutting edges and secondary cutting edge are divided into elements, and the elemental forces are determined by an oblique cutting model and an orthogonal model, respectively. The thrust modeling of the major cutting edges and second cutting edge includes two different kinds of processes: shearing and ploughing. The indentation zone is modeled as a rigid wedge. The force model is verified by comparing the predicted forces and the measured cutting forces.