Investigation of Chip Jamming and Drill Breakage in Deep-Hole Drilling using Smoothed Particle Hydrodynamics

Single-lip deep hole drilling is characterized by a high-quality hole and a high level of productivity achieved. It is performed using high feed rates in a single pass, and, therefore, chips must be removed by the cooling liquid. However, chip jamming is a significant problem when chips wrap around the tool, leading to marks on the borehole wall and an increased drilling torque, potentially causing sudden tool failure. The Smoothed Particle Hydrodynamics method is applied to simulate the challenging fluid flow and elastic bodies. A first approach is developed to model the effects of chip jamming and the possible consequence of drill breakage for a deeper understanding of the process behavior.