Abstract
Effective coolant application is essential to prevent thermo-mechanical failures of gun drills. This paper presents a novel study that enhances coolant effectiveness in evacuating chips from the cutting zone using a computational fluid dynamic (CFD) method. Drag coefficients and transport behaviour over a wide range of Reynold numbers were first established through a series of vertical drop tests. With these, a CFD model was then developed and calibrated with a set of horizontal drilling tests. Using this CFD model, critical drill geometries that lead to poor chip evacuation including the nose grind contour, coolant hole configuration and shoulder dub-off angle in commercial gun drills are identified. From this study, a new design that consists a 20° inner edge, 15° outer edge, 0° shoulder dub-off and kidney-shaped coolant channel is proposed and experimentally proven to be more superior than all other commercial designs.
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