Some Investigations on Drilling of Aluminium Alloy from FEA-Based Simulation Using DEFORM-3D

The production of holes is one of the most common operations among all the machining processes and is more complex than the other metal removal processes. During the drilling, burrs form on both the entry and exit side of the hole as a result of plastic deformation of the material. In order to investigate the burr height, finite element analysis (FEA)-based DEFORM-3D simulations are performed during drilling of aluminium 6061 and 7075 alloys. The influence of variable drill geometry and machining conditions on burr height, thrust force, stresses and strain rates apart from thermal aspects between the drill bit and work pieces are examined. Simulated results analyse the reduction in burr height which can be achieved using the selection of input parameters to attain multiple performance characteristics of output responses, will have a wide range of application prospects saving time and cost of post finishing operation of a drilled hole.