Abstract

Hole making is an essential process in the structural frames of an aircraft and contributes to 40 to 60% of the total material removal operations (Brinksmeier, 1990). This process is commonly divided into short hole or deep hole drilling. Short hole drilling typically covers holes with a small depth to diameter ratio having diameter up to 30 mm and a depth of not more than 5 times the diameter. Meanwhile deep hole drilling caters for holes greater than 30 mm in diameter and the depths are usually greater than 2.5 times the hole diameter. Drilling deeper hole with conventional drills requires pecking method to enable easy flow of the chips out of the hole. Deep hole drilling is more difficult especially when hole straightness is the main concern. Therefore, a usual method is to make a circular cut using a hollow-core cutting tool. This technique allows larger hole diameter to be drilled with lesser power. In addition, holes can be produced in many forms which include through holes or blind holes (Fig. 1). Through hole is one which is drilled completely through the workpiece while a blind hole is drilled only to a certain depth.

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