Simulation and Modeling of Chip Formation in Gun Drilling
Chip formation simulation uses finite element analysis to predict how chips form under different cutting parameters. I have seen it used mostly by cutting tool manufacturers and large aerospace shops. For deep hole drilling, where a broken drill means scrapping the part, simulation pays for itself fast. How Simulation Works for Gun Drilling The simulation models material behavior at the cutting zone using Johnson-Cook constitutive models. These models account for strain hardening, strain-rate sensitivity, and thermal softening. The software divides the tool and workpiece into a mesh of elements, usually 10,000 to 100,000 nodes, and calculates the stresses at each node as the tool advances. ...