摘要：Due to the fact that simulation of drilling was added in commercial finite element analysis (FEA) software only recently, 3D finite element modelling is an invaluable asset during related researches. The present study employs 3D FEA to model the drilling process of Al7075-T6 alloy with solid carbide tooling, investigates important phenomena that occur during drilling and finally compares the simulated results with experimental data. A number of simulations were performed with DEFORM3D™ software at different cutting conditions; cutting speed of 50m/min, 100m/min, 150m/min and feed of 0.15mm/rev, 0.20mm/rev, 0.25mm/rev. The proposed model takes into consideration certain aspects like damage initiation and evolution of the material, contact interface between the drill bit and the workpiece and standard boundary conditions. Eventually, the acquired numerical data for thrust force were compared to the experimental results for the same cutting conditions and parameters. To obtain the experimental data, a series of nine drilling tests were performed. Upon validation of the numerical data, the temperature distribution on the tool tip – workpiece interface, as well as the chip morphology (shape and curling radius) were determined. Results showed a good agreement between the numerical and the experimental data. Specifically, thrust force and chip morphology exhibited an agreement of about 95% and 90% respectively, which confirms the potential of 3D FEA implementation on machining investigations.
