Modeling of burrs during drilling of titanium alloy

Drilling of difficult-to-cut materials like titanium alloy is a complex machining operation. Due to the tool trajectory, the chip thickness changes along the cutting edges and during the tool movement. The aim of this study is to develop a drilling simulation model depending on the tool geometry and cutting data in order to control the final quality of the machined borehole through the size of burrs. First the geometry of the chip is modelled taking into account the parameters defining the tool trajectory and its geometry. An experimental study validates the modelling through measurements of cutting forces and vision camera observations. From this modelling it is possible to optimize the cutting data and cutting tool geometry in order to control the burrs size and thus the final quality of the borehole.