3D finite element modelling of drilling process of Al7075-T6 alloy and experimental validation

In this study, the performances of twist and 3-flute drills in the drilling process of Al7075-T6 aluminium alloy were investigated experimentally and numerically. In the experimental phase, the drilling processes were carried out with the twist and 3-flute drills at three different feed rates (0.05, 0.1, 0.2 mm/rev) and four different cutting speeds (60, 90, 120, 150 m/min). The thrust forces occurring during the drilling processes were measured with a Kistler 9257b dynamometer. In the numerical phase, a 3D finite element model of the drilling process was carried out with Deform 3D V6.1 software. During the finite element analyses of the drilling processes, the thrust forces were numerically obtained and compared with the experimental thrust forces. Also, the torque and tool stress occurring in the drilling process were determined numerically. At the end of the study, the results showed that there is a good agreement between the experimental and numerical results. Additionally, it is shown that the thrust force, torque and tool stress obtained with the twist drill were less than those of the 3-flute drill.