Abstract
In deep hole machining operations with twist drills, whirling vibrations lead to a significant increase in hole diameter deviation and circularity error. In this article, a nonlinear physical model with special consideration of the contact area between the margins of the tool and the workpiece is developed to predict the hole circularity of drilling operations. Numerical simulations are used to study the geometry of the drilling tool to propose a new margin design. In an experimental study, it is shown that the newly developed margin geometry for twist drill tools decreases radial vibrations and leads to a significant improvement in hole diameter deviations and hole circularities.
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