Cutting-fluid flow with chip evacuation during deep-hole drilling with twist drills

• Published in: European journal of mechanics, B, Fluids Vol. 89; pp. 473 - 484
• Main Authors: Baumann, Andreas, Oezkaya, Ekrem, Schnabel, Dirk, Biermann, Dirk, Eberhard, Peter
• Format: Journal Article
• Language: English
• Published: Elsevier Masson SAS 01.09.2021
• Subjects: Chip evacuation; Computational fluid dynamics; Cutting fluid; Deep-hole drilling; Smoothed particle hydrodynamics; Twist drills; Chip evacuation; Smoothed particle hydrodynamics; Cutting fluid; Twist drills; Deep-hole drilling; Computational fluid dynamics
• ISSN: 0997-7546; 1873-7390
• DOI: 10.1016/j.euromechflu.2021.07.003

In this study the important aspects of cutting fluid distribution and the chip evacuation during micro twist deep-hole drilling are investigated using 3D multi-physics simulation methods. A coupled particle simulation is performed to analyze the chip transport by combining Smoothed Particle Hydrodynamics and the Discrete Element Method. Therefore, the transient transport of the chips is compared to a simulation scenario without chips. The coupled particle approach is capable to deal with free surfaces and fluid–solid interactions, that are subject to major topological changes over time. The chip positions resulting from the coupled particle simulation are used to carry out a Computational Fluid Dynamics simulation which considers the physical boundary conditions of the fluid and the process parameters to perform in-depth flow analyses. The results show good qualitative agreement between both simulation methods. Furthermore, the results show that large dead-zones with no fluid or almost zero fluid velocity exist in the flutes and that the chips there only experience a small evacuation force from the cutting fluid. The presented coupled approach of combining CFD and SPH–DEM simulation provide a significant support for future investigations to research the chip transport and to improve the tools and the process further.