Adv. Manuf.
(2018) 6:204–214
https://doi.org/10.1007/s40436-018-0223-z
3D numerical analysis of drilling process: heat, wear, and built-up
edge
Mohammad Lotfi1 • Saeid Amini1 • Ihsan Yaseen Al-Awady1
Received: 28 October 2017 / Accepted: 23 April 2018 / Published online: 29 May 2018
Ó Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature 2018
Abstract In this study, a 3D finite element model is
developed to investigate the drilling process of AISI 1045
steel, and particularly, the heat and wear on the drill faces.
To model drill wear, a modified Usui flank wear rate is
used. Experiments are used for the verification of the
simulated model and the evaluation of the surface rough-
ness and built-up edge. A comparison of the predicted and
experimental thrust forces and flank wear rates revealed
that the predicted values had low errors and were in good
agreement with the experimental values, which showed the
utility of the developed model for further analysis.
Accordingly, a heat analysis indicated that approximately
half the generated heat in the cutting zone was conducted
to the drill bit. Furthermore, material adhesion occurred in
localized heat areas to a great extent, thus resulting in wear
acceleration. A maximum flank wear rate of 0.026 1 mm/s
was observed when the rotary speed and feed rate
were at the lowest and highest levels, respectively. In the
reverse cutting condition, a minimum flank wear rate of
0.016 8 mm/s was observed.
Keywords Drilling  Built-up edge  Heat  Flank wear 
Force
& Saeid Amini
amini.s@kashanu.ac.ir
1
Department of Manufacturing, Faculty of Mechanical
Engineering, University of Kashan, Kashan, Iran
123
1 Introduction
Drilling is the most common machining process in which,
in the related industries, hole generation is required more
than other existing shapes [1]. Similar to other machining
methods, low surface roughness and cutting forces coupled
with long tool life are desirable. One negative factor that
prevents manufacturers from meeting these desirable con-
ditions in drilling is the formation of built-up edge (BUE).
This factor could reduce surface quality and tool life, and
its formation is directly dependent on the value of heat
generated in the cutting zone and tool faces [2]. In contrast
to the simple measurement of cutting forces and surface
roughness in experiments, it is difficult to perform an
analysis of the heat generated on the drill faces when the
drill bit is in the hole. Thus, an alternative method of
evaluating the generated heat in the drill bit could be the
use of a finite element (FE) simulation. However, to obtain
a reliable model, the theoretical models of friction, dam-
age, and flow stress should be accurately defined based on
the experimental data and previous studies. Some of the
papers in this field are represented to be reviewed. Bagci
and Ozcelik [3] simplified the drilling simulation using a
2D model for analyzing the effect of sequential dry drilling
operations on the drill bit temperature. They observed a
good agreement between the predicted results and the
experimental results. The FE model was based on
Lagrangian explicit in Ref. [3]. Wu and Han [4] proposed a
2D heat analysis model for predicting the temperature
generated on the drill faces. They reported that the exper-
iment values were in good agreement with the predicted
values with an approximate error of 15%. Guo and Dorn-
feld [5] simulated the burr formation at the exit point of
drilled holes in the drilling of AISI 304 stainless steel; and
a 3D nonlinear thermo-elastic-plastic FE model was
3D numerical analysis of drilling process: heat, wear, and built-up edge 205

developed in order to estimate the ductile material fracture.

After running the simulations, it was revealed that the
dominant roles in the direction of burr formation belonged
to shearing and plastic bending. The drilling of AISI 1045
steel was simulated by Nan et al. [6] with the development
of a 3D FE model. They used the Johnson-Cook flow stress
and failure models in the simulations. Furthermore, to
predict the friction conditions, a friction coefficient of 0.6
was used. The influence of variations in the feed and rotary
speeds on the chip geometry, torque, and thrust force were
investigated. Chatterjee et al. [7] used a combination
method (a 3D FE simulation and statistical work) to opti-
mize the cutting parameters of the drilling process. They
used a shear friction model with a friction value of 0.6 at
the tool-chip interface and the Johnson-Cook model to
predict the material flow stress. Abdelhafeez et al. [8]
applied a coupled Eulerian-Lagrangian FE model for sim-
ulating the drilling process. A twist drill bit has been
modeled based on a Lagrangian formulation wherein the
mesh followed the material displacement while a non-
translation (independent Eulerian mesh) was used for the
workpiece. They utilized this 3D model to evaluate the Fig. 1 Drill bit and its CAD model
different shapes of burr formation in the simulation work.
On reviewing the aforementioned studies, it can be AISI 1045 steel has been selected for the drilling process
concluded that the majority of the simulation works for which it was prepared in the strip form with dimension
focused on the simulation of chip formation rather than the 150 mm 9 75 mm 9 8 mm. In this condition, the hole
evaluation of the cutting tool conditions, such as the heat depth obtained was constant at 8 mm, which was equal to
and especially the wear generated at the tool faces during the thickness of the workpiece. In the simulation, a 5-mm-
the simulation of the drilling process. The aim of this study thick workpiece was modeled. The properties of the drill
is to develop a 3D FE model for the drilling process to bit and workpiece material are listed in Tables 1 and 2.
predict the heat and flank wear generated on the drill faces.
Accordingly, a modified Usui flank wear rate model is 2.2 Mesh design and boundary conditions
used.
The Lagrangian formulation coupled with the maximum
interference depth remeshing criterion was employed to
2 Simulation and experiment simulate the chip formation and to remesh the workpiece
during the distortion of elements. In this study, the default
2.1 Drill and workpiece element size value of 0.7 has been taken into consideration
for the remeshing criterion.
High-speed steel (HSS) drill bits from China Omega Drill The workpiece was meshed with 30 000 tetrahedron
Co. were used to drill the workpiece material. Owing to the mesh elements in which a window of a higher mesh density
complexity of the drill bit geometry and the requirement of (of size 0.01) was located in the drilling zone owing to the
a precise model, the drill bit was scanned under a 3D severe distortion of the workpiece elements that results
optical scanner device for obtaining its cloud of points. from higher plastic deformation. The drill bit was meshed
Subsequently, the extracted point-wise part has been with 23 000 tetrahedron mesh elements. A mesh window
modeled using CATIA V5 software. Finally, the model was was also used at the tip of the drill bit for obtaining a
saved in the STL format and was then imported to precise calculation of the temperature and wear in this
DEFORM-3D software. Figure 1 shows the drill bit. Its region (see Fig. 2). For modeling the workpiece, a conical
geometrical dimensions were as follows: diameter 5 mm, concave surface was pre-built on the surface. As shown in
point angle 120°, helix angle 28°, pitch 28 mm, and total Fig. 2, the bottom and top surfaces of the workpiece were
length 86 mm. It should be noted that, to reduce the left free while its around was fixed in the x, y and z direc-
computation time, the superfluous part of the drill bit has tions. The feed motion was applied to the drill bit in the
been neglected in the simulation.

123
206 M. Lotfi et al.

Table 1 Properties of AISI 1045 [4, 6, 9]

Temperature/°C Specific heat/ Thermal conductivity/ Poisson’s Density/
(J°Ckg-1) (W°Cm-1) ratio (kgm-3)
20 200 400 600 800

Elastic modulus/GPa 215 210 165 160 90 420 ? 0.504 T 48.3 - 0.023 T 0.3 7 800
Thermal expansion/ 10.1 12.0 14.0 16.6 18.0
(9 10-6 °C-1)

Table 2 Properties of HSS [4, 6, 9]

Properties Temperature/°C
20 50 200 500 600 700 900

Specific heat/(J°Ckg-1) – 473.11 494.04 – 457.81 – 487.12

Thermal conductivity/(W°Cm-1) 27.21 – 25.96 25.96 – 25.12 25.12

     
e_ T  Tr m
r ¼ ðA þ BðeÞn Þ 1 þ C ln 1 ;
e_0 Tm  Tr
ð1Þ
where A, B, C, n, and m are the yield strength, hardening
modulus, strain rate sensitivity, strain hardening, and
thermal softening exponent, respectively [11]. Moreover,
e_0 is the reference of the plastic strain rate, e_ the plastic
strain rate, e the equivalent strain, r the equivalent flow
stress, Tr the reference temperature (20 °C), Tm the melting
temperature (1 460 °C), and T the temperature. Table 3,
[12] shows the constant J-C values used in the simulation.

2.4 Damage model

In general, damage occurs whenever the critical value of

the model is met during the process. In this study, the
Oyane criterion, which is as a function of the mean stress
(rm) and effective stress (r),
 is used.
Z ef  
1 rm
C2 ¼ 1þ de: ð2Þ
Fig. 2 Meshed objects 0 C1 r
Equation (2) represents this model [13]. ef , e, C1, and C2
are the fracture strain, equivalent strain, model coefficient,
direction opposite to the z-direction while the drill bit and critical damage value, respectively. Based on the study
rotated clockwise. by Sowerby and Chandrasekaran [14], the values in
Table 4 have been used.
2.3 Flow stress
2.5 Friction model
The important effects such as strain hardening, strain rate,
and thermal softening can be simulated using a compre- The Zorev model is used for predicting the friction con-
hensive model presented by Johnson and Cook (JC) [10] as ditions in the drill-chip contact zone. The contact length is
the flow stress model. This model is represented as divided into two zones in this model. Near the cutting edge,
there is a sticky zone that is defined by sf ¼ mk, and further
contact, i.e., the sliding zone, is defined by sf ¼ lrn . k and

123
3D numerical analysis of drilling process: heat, wear, and built-up edge 207

Table 3 J-C values for AISI 1045 steel [12] The experimental flank wear rates were calculated based
A/MPa B/MPa C n m
on the drilling time (t) and flank wear (VB ) propagated on
the flank face of the drill bit
553.1 600.8 0.013 4 0.234 1
VB
V_ B ¼ ; ð5Þ
t
LN
t¼ ; ð6Þ
rf
Table 4 Damage data based on Oyane criterion for AISI 1045 steel
Parameters Values where L is the hole depth (mm), N the number of drilled
holes, r the rotary speed (r/s), and f the feed rate (mm/r). In
ef 0.616 this study, L = 8 mm and N = 3.
C1 0.480
C2 0.662 2.7 Heat transfer

Some part of the work done during the plastic deformation

rn are the shear flow stress of the working material and
is converted to heat (q_ p )
interface pressure, respectively. Furthermore, m is the shear
friction factor, and l is the Coulomb friction factor. Based f w_ p
q_ p ¼ : ð7Þ
on this model, at each contact node, if lrn  mk, the q
contact sticks, and if lrn \mk, the contact slides. This
The generated heat causes an increase in temperature at
process is automatically performed in the DEFORM soft-
the cutting zone. A small percentage of this heat is trans-
ware. Based on the Refs. [15, 16], the following values
ferred to the environment through convection [19]. In this
were used: l = 0.4 and m = 0.9.
equation, w_ p , q, and f are the rate of plastic work, density,
and fraction of plastic work converted into heat,
2.6 Wear model
respectively.
When the chip formation is continued and it reaches the
Using the original Usui wear rate model
tool rake face, a second source of heat is generated owing
B
w_ ¼ Avs rn eT ; ð3Þ to the friction at the tool-chip interface (q_ f ). Equation (8)
represents the heat generated owing to friction
where rn , vs , and T are the local values of the contact
pressure, sliding velocity, and temperature at tool-chip q_ f ¼ nf sf vs ; ð8Þ
interface, respectively [18]. The wear rate w_ is calculated where nf , sf , and vs are the frictional work conversion
in the directions that are perpendicular to the tool faces. factor, friction stress, and sliding velocity, respectively.
This model can be used only if the crater wear rate is
selected as the wear criterion for the prediction of the wear
rate because this criterion is perpendicular to the tool rake
face. Furthermore, the original model cannot reliably be
used when the flank wear rate (V_ B ), which is tangential to
the tool flank face, is selected as the wear criterion.
Therefore, a modified Usui flank wear rate model that takes
into consideration the tool clearance angle (c) is used [17]
Tb
avs rn e
V_ B ¼ : ð4Þ
tan c
These variables are computed at the end of each cutting
time increment in the simulation (dt ¼ 5:65  105 ). The
average tool clearance angle was 12 . It should be noted
that, as the clearance angle of the drill bit was varied along
the cutting edge, the average value of the clearance angle
was used. a and b are the constant parameters of this model
and are calibrated in an iteration comparison of the flank
wear rate (mm/s) achieved in both the simulation and
experimental cutting processes. Fig. 3 Experimental set-up

123
208 M. Lotfi et al.

In such conditions, heat is conducted from the deformed (ii) 10% of the remaining plastic work is stored;
chip to the tool rake face, thus resulting in an increase in (iii) 100% of the frictional work is converted into heat;
the tool temperature [20]. (iv) A heat partitioning factor of 0.5 is used.
q_ int ¼ hint ðTW  TT Þ; ð9Þ Furthermore, the following three modes were considered
where q_ int is the heat flux into the cutting tool at the tool- for the heat transfer conditions:
chip interface. hint , TW , and TT are the interface heat (i) The areas far from the cutting zone remained at
transfer coefficient, workpiece temperature, and cutting 20 °C, i.e., at room temperature.
tool temperature, respectively. (ii) The heat convection value of 20 W/(m2°C) was
Based on Refs. [21, 22], the following thermal boundary considered for the surfaces of the drill bit,
conditions were applied during the simulation: workpiece, and deformed chips in contact with
(i) 90% of plastic work is converted into heat; the environment [17].
(iii) Assuming that the drill-chip contact is thermally
perfect, a large heat conduction value of 105 kW/
Table 5 Cutting parameters and run numbers
(m2°C) was applied [23, 24].
Run Feed speed/ Rotary speed/ Hole depth/
No. (mmmin-1) (rmin-1) mm
2.8 Cutting conditions
1 83 830 8
2 124 830 8
A 4301 computer numerical control machine manufactured
3 165 830 8
by Tabriz Machinery Manufacturing Co. was used in the
4 83 890 8
experiments. The experimental set-up is shown in Fig. 3.
5 124 890 8 As previously explained, the drilling depth was constant
6 165 890 8 and equal to the workpiece thickness. The variable
7 83 950 8 parameters were the feed rate and rotary speed for which
8 124 950 8 three levels were considered. In particular, each run was
9 165 950 8 performed three times to ensure the repeatability of the
results. A total of 27 experimental tests were performed in
this study (see Table 5).

Fig. 4 Simulated chip formation in drilling (feed 124 mm/min, speed 950 r/min)

123
3D numerical analysis of drilling process: heat, wear, and built-up edge
Fig. 5 Thrust force comparison
To measure the thrust force during the process, a Kistler
dynamometer (9257B type) with 6° of freedom was used.
The roughness of the drilled holes order to was measured
using a Mahr roughness tester (Mar Surf PS1).In addition, a
vision measuring microscope (Easson C-3020 VMM-type)
was used to study the drill bit and deformed chips after
performing the cutting tests.
3 Results and discussion
3.1 Model verification
The drilling tests were performed based on Table 5. During
each cutting test, the thrust force was measured using a
dynamometer. For the same cutting conditions, simulation
runs were performed as shown in Fig. 4. Figure 4 shows
the process of chip formation at various simulation steps.
209
In order to verify the developed FE model, the simulated
thrust forces were compared with those measured during
the experimental works. This comparison is shown in
Fig. 5. Figure 5 is represented in three parts. In each part,
the variation in the thrust forces is shown at different feed
rates when the cutting speed is constant. Accordingly, it
can be clearly observed that the predicted values are in
good agreement with the experimental values, which
ensures the utility of the model for further analysis. It
should be noted that the average values of the three mea-
surements of the thrust forces (including the replications)
are presented in Fig. 5.
With respect to the limitation of this study, the varia-
tions in the rotary speed did not have a significant effect on
the forces. However, the forces were slightly reduced
owing to an increase in the rotary speed. In contrast, the
feed variations have a significant effect on the process. The
increase in the feed rate from 83 mm/min to 165 mm/min
caused an increase in the thrust forces in both the simula-
tion and experimental works. This can be attributed to an
increase in the uncut chip thickness. The greater the
increase in the uncut chip thickness owing to the increment
in the feed rate, chip formation (shearing action) is made
harder. Furthermore, in such conditions, the length of the
drill-chip interface increases, thus resulting in a higher
frictional force [25].
3.2 Heat and BUE analysis
In the drilling process, some factors, such as the chip for-
mation, heat, drill-chip friction, and BUE, can directly
affect each other. Generally, long straight or helical shapes
are the common forms of the generated chips in the drilling
of AISI 1045 steel that twist around the drill bit. The
evacuation of these types of chips from the cutting zone is
difficult [26]. Therefore, it results in an increased frictional
force at the drill-chip interface, thus resulting in an incre-
ment in temperature and heat localization in this area. The
result of high temperatures is BUE formation. Therefore, a
heat and BUE analysis is presented in this section. In the
DEFORM software, the temperature of the cutting zone
and the heat transferred to the drill bit can be individually
investigated. The heat analysis of the drill faces (after
running 2 500 simulation steps) and BUE were performed,
as shown in Fig. 6. It can be ascertained from Fig. 6 that
less than half of the generated heat in the cutting zone was
conducted and transferred to the drill faces. It should be
noted that, based on the simulation results, temperature
values of 406 °C, 477 °C, and 510 °C were generated in
the cutting zone for feed rates of 83 mm/min, 124 mm/
min, and 165 mm/min while lower temperatures were
distributed on the drill faces. This meant that the remaining
heat was not transferred to the drill faces but was stored in
123
210 M. Lotfi et al.

Fig. 6 Heat and BUE on drill faces at different feed rates (rotary speed = 890 r/min)

the workpiece or transferred to the environment through

convection. Finally, Fig. 6 clearly shows that the reason for
the increase in the BUE with the increase in the feed rate
was the increase in the temperature distribution on the drill
faces; the high temperatures were localized at the cutting
edges (lip length).
The temperature of the drill bit at different cutting
conditions is depicted in Fig. 7. Although an increase in the
rotary speed results in an increase in the temperature, the
effect of feed rate increment is more significant.

3.3 Wear analysis

Fig. 7 Predicted temperature on drill faces at different rotary speeds
After running some trial-and-error works between simula- (r/min) and feed rates (mm/min)
tion and experiment, the following values:

123
3D numerical analysis of drilling process: heat, wear, and built-up edge 211

 N 1
a ¼ 1:2e5 mm , b ¼ 1 250, were found to produce
s
precise results during the simulation.
The results of the experimental and predicted flank wear
rates are listed in Table 6 and illustrated through a graph in
Fig. 8. A comparison of the obtained results shows that a
similar trend exists between the experimental and predicted
flank wear rates. Accordingly, the flank wear is higher in
the case of low feed rates as compared with high feed rates
while the rate of flank wear is higher in the case of high
feed rates as compared with low feed rates. It is expected
that higher feed rates would accelerate the rate of wear
propagation; however, for a constant cutting length (three
holes of 8-mm length), lower flank wear is generated. Thus,
a decrease in the cutting time caused by an increase in the
feed rate could compensate for the negative effect of the
higher wear rate due to the increase in the feed rate. It
should be noted that this is a limitation of this study, and
the obtained results may be different for a longer cutting
length or deeper holes in the experiment.
Overall, the maximum (Run 3) and minimum (Run 7)
flank wear rates were 0.026 1 mm/s and 0.016 8 mm/s,
respectively. The flank wear rates increased owing to an
increase in the feed rate while an increase in the rotary
speed caused a decrease in the flank wear rates.
Moreover, Fig. 9 presents the wear distribution on the
drill faces for both the experiment and simulation. As can
be observed, on increasing the simulation steps from 1 500
to 3 500 and engaging the drill lips with the workpiece, the
wear is also distributed along the lips.

3.4 Chip geometry

In order to investigate the simulated chip geometry, the

Fig. 8 Comparison of experimental and predicted flank wear rates workpiece material damage values should first be

Table 6 Comparison of flank wear rates (mm/s) at different run numbers

Run No. r/(rmin-1) f/(mmmin-1) t/s Experimental VB Experimental V_ B Predicted V_ B

1 830 (13.8 r/s) 83 (0.1 mm/r) 17.34 0.352 0.020 3 0.019 7

2 830 124 (0.15 mm/r) 11.56 0.267 0.023 1 0.024 3
3 830 165 (0.2 mm/r) 8.67 0.226 0.026 1 0.025 1
4 890 (14.8 r/s) 83 16.17 0.305 0.018 9 0.019 4
5 890 124 10.78 0.239 0.022 2 0.023 5
6 890 165 8.08 0.207 0.025 7 0.024 8
7 950 (15.8 r/s) 83 15.15 0.254 0.016 8 0.018 8
8 950 124 10.10 0.217 0.021 5 0.022 4
9 950 165 7.57 0.173 0.022 9 0.022 7

Fig. 9 Simulated and experimental drill wear (Run 3)

123
212 M. Lotfi et al.

Fig. 10 Damage values at different feed rates

evaluated. This is because, other than the drill geometry

and workpiece material, this value directly defines the
geometry of the deformed chips formed in the simulation.
Accordingly, the damage values at various feed rates are
illustrated in Fig. 10. From Fig. 10, it can be ascertained
that the damage value varied significantly with each vari-
ation in the feed rate. Furthermore, the damage value was
the highest for the lowest value of feed rate and the damage
value was the lowest for the highest value of feed rate. This
result may be explained by analyzing drill rake face. As
shown in Eq. (10), the drill rake angle (a), which varies
along the lip length, can be calculated
rx tan x
tan a ¼ : ð10Þ
R sin u
R, rx, x, u, f, and D are the drill radius, radius of the
selected point at the lip length, helix angle, half the drill
point angle, feed rate, and drill diameter, respectively [27].
Owing to the combined action of the feed rate and rotary
speed in the drilling process, each point on the lip length
traverses a helical path; a more precise calculation of the
rake angle during the operation (aw ) can be obtained by
using
f
aw ¼ a þ tan1 : ð11Þ
pD
In Eq. (11), the rake angle is summed with the term of
the helical angle generated by the feed motion.
According to Eq. (10), a decrease in the feed rate results
in a decrease in the drill rake angle. According to the
previous studies [28–30], a larger bending moment that
causes chip breakage is applied at the root of the deformed
chip when the tool rake angle is reduced owing to an
increase in chip curling during its formation. Figure 11
Fig. 11 Comparison of chip geometry
demonstrates that the damage value was properly selected
in this study. A helical coil shape that was similar to that 3.5 Surface roughness
observed in experimental situations was generated in the
simulation. Each cutting test was performed three times. For the
analysis of the surface roughness (Ra ), three points on the
drilled surface (third hole) were selected and the surface
roughness was measured using a roughness tester. The

123
3D numerical analysis of drilling process: heat, wear, and built-up edge
Fig. 12 Surface roughness
results as well as their average values are presented in
Fig. 12. The results are shown according to the run num-
bers listed in Table 5. The overall measured values lie in
3 – 7 lm range. In particular, an increase in the rotary
speed significantly enhanced the surface quality owing to
the superior shearing action thus obtained [25]. This result
is the opposite of that observed for the feed rate wherein an
increase in this parameter results in a reduction in the
surface quality (increased surface roughness). This can be
attributed to the increase in the BUE formation. As illus-
trated in Fig. 6, the size of the BUE was increased owing to
an increase in the feed rate. Generally, when some parts of
the working material adhere to the drill body and forms
BUEs, some parts of the attached material are separated
from the drill bit and adhere to the drilled surfaces or
deformed chips. The action of adhesion and separation
occurs continuously during the drilling process. This,
therefore, causes the surface quality of the drilled holes to
be reduced in higher feed-rate ranges.
4 Conclusions
The drilling process of AISI 1045 steel was investigated
using two methods: experimental and simulation works.
The following are the conclusions drawn from the
investigation:
(i) The comparison of the results shows that the
developed model is reliable for numerical
analysis of various parameters.
(ii) An increase in the rotary speed from 830
r/min to 950 r/min caused the thrust force to
be reduced by approximately 140 non average
while an increase in the feed rate from
83 mm/min to 165 mm/min caused the thrust
force to be increased by approximately 410
non average.
213
(iii) A heat analysis showed that approximately
half of the generated heat in the cutting zone
was conducted to the drill bit. Furthermore, it
was clearly observed that the cause of the
increase in BUEs owing to the increase in the
feed rate (observed in experiments) was the
increase in the localized temperature at the
cutting edge.
(iv) The maximum and minimum flank wear rates
were 0.026 1 mm/s and 0.016 8 mm/s, respec-
tively. The flank wear rate increased with an
increase in the feed rate while an increase in
the rotary speed caused a decrease in the feed
rate.
(v) It was observed that a decrease in the cutting
time owing to an increase in the feed rate
could compensate for the negative effect of
the higher wear rate owing to the increase in
the feed rate.
(vi) The damage analysis indicated that the dam-
age was the highest (D = 0.301) for the lowest
value of feed rate owing to the lower value of
drill rake angle in the lower feed rates.
Furthermore, the continuous helical coil shape
was the common shape of the deformed chips
in the drilling of AISI 1045 steel, which was
identical in both the experiment and
simulation.
(vii) The decrease in the surface quality owing to
the increase in the feed rate was attributed to
the BUEs that increased owing to the increase
in feed rate. This effect was enhanced at
higher tool rotary speeds.
(viii) The developed model or the same process of
development can be used for the further
analysis of drilling or other machining pro-
cesses in order to increase the knowledge of
cutting processes and reduce the time and
costs that are typically required for experi-
mental tests.
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