Abstract
Drilling is one of the most useful metal cutting processes and is used in various applications, such as aerospace, electronics, and automotive. In traditional drilling methods, the thrust force, torque, tolerance, and tribology (surface roughness) are related to the cutting condition and tool geometry. In this paper, the effects of a pre-center drill hole, tool material, and drilling strategy (including continuous and non-continuous feed) on thrust force, surface roughness, and dimensional accuracy (cylindricity) have been investigated. The results show that using pre-center drill holes leads to a reduction of the engagement force and an improvement in the surface quality and cylindricity. Non-continuous drilling reduces the average thrust force and cylindricity value, and High Speed Steels HSS-Mo (high steel speed + 5–8% Mo) reduces the maximum quantity of cutting forces. Moreover, cylindricity is directly related to cutting temperature and is improved by using a non-continuous drilling strategy.
Highlights
Drilling is one of the popular machining methods and is used in most assembly processes
Klocke and Krieg studied various properties of coated drills. They found tool coating life is associated with workpiece materials due to the formation of a built-up edge on cutting edges, and this problem can be solved by using appropriate cutting fluids
Nozzle, workpiece material, and minimum quantity lubricant (MQL) particle size are significant to the generation of thrust force and surface roughness [7]
Summary
Drilling is one of the popular machining methods and is used in most assembly processes. Materials 2018, 11, 140 and analysed the effect of the cutting condition on thrust force, torque, and tool wear They found that WC-Co (Tungsten carbide + Cobalte) is an acceptable tool for drilling BMG, and by increasing the cutting speed and decreasing the feed rate the mentioned results were improved. Using design of experiment methods, such as Taguchi and response surface, showed that feed rate and cutting speed are the most influential parameters on the drilling of steels Different machining methods, such as ultrasonic drilling, and tool selection leads to better surface quality and drilling of soft materials, such as Al, and helical milling increases fatigue life [18,19,20]. A full factorial design of experiment (DOE) has been selected to achieve higher accuracy
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