Drilling force modeling promotes new drill bits and drilling processes

The research on drilling force modeling has been continuously advancing alongside the development of new drill bit designs and drilling technologies. WuSM and colleagues have contributed significantly to the development of group drilling force models. Among their early contributions, LeeSW (1986) and FuhKH (1987) introduced a cutting force model for group drills by applying a bevel cutting model to the main cutting edge and a right-angle cutting model to the secondary edge. HuangHT (1992) proposed a mechanical-based approach to predict axial force and torque in group drills, drawing from conventional twist drill models. Armarego EJA and ZhaoH (1996) developed predictive models for thin core standard twist drills, thin core multi-groove drills, and arc center edge twist drills. Bhatnagar N (2004) focused on the unintended damage caused when drilling anisotropic fiber-reinforced composites with different drill tips, and constructed a model to estimate axial force and torque during such operations. SahuSK (2004) introduced a chip breaker cone taper drill model that was calibrated using various chip breakers, making it adaptable to any chip breaker design. ElhachimiM (1999) developed a high-speed cutting force model using both right-angle and bevel cutting approaches, validated through experiments conducted at speeds ranging from 4000 to 18000 rpm and feed rates between 0.12 mm/r and 0.36 mm/r. The results showed good agreement with the model's predictions. WangLP (1998) analyzed the vibration behavior of individual cutters on the main and chisel edges to determine the dynamic mechanical properties of the entire drill bit, leading to a model for predicting axial and torque forces during vibration drilling. As drilling technology evolved, researchers found that traditional mechanical models were insufficient for newer drill types due to structural differences. StepensonDA (1992) addressed this by calibrating a unit tool bevel cutting force model using extensive turning experiments, enabling accurate predictions of torque, axial, and radial forces for gray cast iron drilling with carbide or studded carbide drills. LinGC (1982) and Watson AR (1985) highlighted that previous models underestimated torque and axial force due to poor chip evacuation. This led to the development of the unit tool nonlinear synthesis method, which allowed for more accurate modeling of complex blade bits. WangJL (1994) further refined this approach by studying chip evacuation and applying the nonlinear synthesis method to build a general cutting force model for any blade bit. Beyond the basic geometry of the drill, numerous process-related factors influence drilling forces. In 1996, ChandrasekharanV et al. considered manufacturing tolerances and sharpening errors—such as contour deviations of the main edges, radius errors, and axial deflection—to develop a full three-dimensional cutting force model for conical drill bits. This model was later extended to predict forces for various drill types, including group drills. SriramR developed a model that accounted for the effects of drill sharpening and installation errors on radial force during drilling. In 2001, GongYP and EhmannK created a detailed model for micro-hole drills, incorporating the impact of drill geometry, sharpening, mounting errors, and bit deflection on dynamic cutting thickness and area for the main and chisel edges. Their work provided a more comprehensive understanding of how these factors interact to affect drilling forces.

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