Drilling is a standard process for producing holes in metal materials. With an increased hole depth the demands increase on both machine and tool. Deep hole drilling is a complex process which ischaracterized by a high metal removal rate and hole accuracy. A hole deeper than ten times the diameter can be considered a deep hole which requires a specialized drilling technique. During adeep hole drilling process, the forces generated on the deep hole drill give a rise to a resultant radial force. The resultant radial force pushes the drill in a radial direction during a drilling operation. The radial force direction is of crucial importance in regard of tool guidance, stability and hole size accuracy. This force affects tool performance, reduces tool life and has an impact on the bore surface. Due to the complex nature of deep hole drilling, Sandvik Coromant wishes to get a better understanding of how their current deep hole drilling tools are balanced. The purpose of this study is to conduct a survey of a number of drills of Sandvik Coromant deep hole drill assortment. The main aim of this study is to calculate and measure the resultant radial force generated during a deep hole drilling operation. The forces are calculated with the aid of a calculation program and test-runs on a number of drills. This report presents the calculated magnitude and direction of the resultant radial force duringentrance, full intersection and at the exit of the workpiece. In addition to the measured values of theresultant radial force during entry and full intersection. Four different drill geometries are evaluated which of two are competitor drills. A deep hole drill geometry is re-modified in aspect to drill stability based on the outcome of the measured and calculated results. The results acquired from the performed calculation and measurements of the resultant showed that the resultant radial force acts in an angular direction that was outside the range between the support pads. This true for three of the four evaluated drill geometries. There were minor differences between the measured and calculated forces which enforce the reliability of the used calculation program. The modified drill geometry of a deep hole drill gave an indication of which geometry variables have impact on the resultant radial force magnitude and angular direction. The data presented in this report can be a base for future development of a deep hole drill toolgeometry in regard to the resultant radial force. Variables affecting the calculated results and theresultant radial force are presented and discussed. The study is concluded with suggestions of futurework based on the acquired data.

Automated narrow-gap girth-butt welds are replacing conventional welding methods to join sections of austenitic stainless steel pipe in the primary circuit of Pressurised Water Reactors, to reduce manufacturing costs and improve quality. To ensure the safe operation of these systems, reliable structural integrity assessments have to be undertaken, requiring the mechanical properties of welded joints to be characterised alongside the weld residual stress magnitude and distribution.This research project characterised, for the first time, the weld residual stress field and the tensile and ductile fracture toughness properties of a 33 mm thick narrow-gap 304L stainless steel pipe weld. The residual stress was characterised using two complementary approaches: deep hole drilling and neutron diffraction. A novel neutron diffraction scanning technique was developed to characterise the residual stress field, without cutting an access window into the component, leaving the original weld residual stress field undisturbed. A modified deep hole drilling technique was developed to characterise the residual stress retained in fracture mechanics specimens extracted from the pipe weld in two orientations. The modified technique was shown to measure the original weld residual stress field more accurately than through conventional deep hole drilling. Residual stresses, exceeding 50% of the weld material proof strength, were retained in axially-orientated fracture mechanics specimens.Tensile tests showed that the weld was approximately 60% overmatched. It was demonstrated that neither retained residual stress, nor specimen orientation, had a discernible effect on the measured fracture toughness of the weld material. In less ductile materials, however, the level of retained residual stress may unduly influence the measurement of fracture toughness. At initiation, the fracture toughness properties of both the parent and weld materials were far in excess of the measuring capacity of the largest fracture mechanics specimens that could be machined from the weld.The influence of residual stress and fracture toughness on the performance of narrow-gap welded pipework was investigated. Full elastic-plastic finite element analyses were used to model the pipe weld, containing a postulated defect under combined primary and secondary loading. The results, applied within the framework of an R6 structural integrity assessment, compared different plasticity interaction parameters on the prediction of failure load; the conventional ρ-parameter approach was compared with the recently developed, more advanced, g-parameter. It was shown that the g-parameter significantly reduced the conservatism of the ρ-parameter approach. However, for this pipe weld, plastic collapse was predicted to precede failure by ductile initiation, suggesting that a plastic collapse solution may be an appropriate failure criterion to use in structural integrity assessments of similar component and defect combinations.

Les travaux effectués au cours de cette thèse ont pour objectif d’étudier et de modéliser une opération de soudage multipasse d’un acier à haute limite d’élasticité utilisé en construction navale. Dans ce cadre il s’agit de prédire les conséquences métallurgiques et mécaniques du procédé et tout particulièrement la répartition et l’intensité des contraintes résiduelles post- soudage nécessaires pour analyser l’intégrité de la structure navale en service. Deux maquettes représentatives d’un joint d’angle en Té ont permis de caractériser l’évolution des cycles thermiques, de la microstructure et des contraintes résiduelles (estimées par les méthodes du contour et du trou profond) après chaque passe de soudage. La suite de l’étude concerne la caractérisation et la modélisation du comportement thermo-métallurgique et thermo- mécanique des différentes phases apparaissant au cours du soudage. La dernière partie porte sur l’implémentation des modèles retenus dans le code de calcul élément finis Abaqus à l’aide de sous-programmes spécifiques. Une étape de transition d’échelle a permis de décrire le comportement thermomécanique multiphasé de cet acier. Des calculs préliminaires ont été conduits pour valider l’implémentation des modèles sur des cas simples. Différents couplages ont été réalisés, soit une analyse thermique puis thermo-métallurgique, pour estimer la dureté après chaque passe et enfin métallurgique-mécanique pour prédire les contraintes résiduelles pour le procédé de soudage multipasse. Les résultats des calculs éléments finis ont été discutés et comparés aux résultats expérimentaux obtenus dans la première partie de cette étude. / This thesis aims at studying and modeling a multipass welding operation of a high strength steel used in shipbuilding. In this framework, work focus on predicting the metallurgical and mechanical consequences of the process and, in particular, the residual stress distribution after welding. Since residual stresses can be detrimental to the performance of the welded product, their estimation is essential and numerical modelling is useful to predict them. Two welding mock-ups which are representative of a T- joint were used to characterize the evolution of thermal cycles, microstructure and residual stresses (measured by contour method and deep hole drilling) after each welding pass. Metallurgical and mechanical behaviors were thoroughly characterized in order to feed numerical models with reliable constitutive equations. The last part deals with the implementation of the models in the finite element calculation code Abaqus using specific subroutines. A scale transition procedure has been added to describe the thermomechanical multiphase behavior of the steel. Preliminary calculations were carried out for simple cases to validate the implementation of models. Different numerical couplings were made. First a thermal analysis then a thermo-metallurgical analysis, to estimate the hardness after each welding pass. Finally, a metallurgical-mechanical analysis is achieved for the prediction of residual stresses due to multipass welding. The results of the finite element calculations were discussed and compared with the experimental results obtained in the first part of this work.