Finite element modelling of countersinking process

This paper presents a new approach for countersinking process modelling in order to obtain normalised specifications for the screw hole and countersink. The developed Finite Element (FE) model has permitted to study the variation of countersink geometry in relation to the initial diameter of the drilled hole, the fillet value, the applied force and the distance between the die surface and the punch. On the basis of obtained results, it is possible to set optimal conditions to achieve the normalised dimensions of the countersink. The FE results were in good agreement with the experimental tests.