Investigation of Chip Evacuation in Ejector Deep Hole Drilling using Mesh-Free Simulation Methods

Ejector deep hole drilling is advantageous due to its high material removal rate and bore quality without requiring a complex sealing system for drilling applications with large length to diameter ratios. Sufficient supply of metal working fluid and efficient removal of the swarf is crucial, which would otherwise lead to poor bore quality, increased friction, and tool wear. Based on experimentally obtained chip shapes, a coupled SPH-DEM simulation model was used to enhance the understanding of the highly complicated and dynamic chip evacuation conditions. A comparison of different tool head designs and their influence on the chip evacuation is presented.