The research on drilling force modeling has been continuously evolving alongside the advancement of new drill bit designs and drilling techniques. WuSM and colleagues have contributed significantly to the development of group drilling force models. Among them, LeeSW (1986) and FuhKH (1987) introduced a cutting force model for group drills by applying a bevel cutting model for the main cutting edge and a right-angle cutting model for the secondary cutting edge. Later, HuangHT (1992) proposed a mechanical model to predict the axial force and torque of group drills based on conventional twist drill principles.
Armarego EJA and ZhaoH (1996) developed cutting force prediction models for thin-core standard twist drills, thin-core multi-groove drills, and arc-center-edge twist drills. Bhatnagar N (2004) investigated unintended damage in anisotropic fiber-reinforced composites during drilling with four different drill tip geometries and established a model for predicting axial force and torque. SahuSK (2004) introduced a chip-breaker cone taper drill cutting force prediction model, which was calibrated using drills with various chip breakers and is applicable to any chip breaker shape.
ElhachimiM (1999) developed a high-speed cutting force model using right-angle and bevel cutting models, testing at speeds between 4000 r/min and 18,000 r/min, and feed rates from 0.12 mm/r to 0.36 mm/r, with results closely matching the model predictions. WangLP (1998) analyzed the vibration of individual cutters on the main and chisel edges to obtain dynamic mechanical properties of the entire drill bit, leading to a model for dynamic axial force and torque during vibration drilling.
As the field progressed, researchers realized that older mechanical models were not suitable for newer drill types due to structural differences. StepensonDA (1992) used a unit tool bevel cutting force model calibrated through extensive turning experiments to develop torque, thrust, and radial force prediction models for drilling gray cast iron with any bladed carbide or studded carbide drill. LinGC (1982) and Watson AR (1985) highlighted that underestimation of torque and axial force was due to chip evacuation, which led to the development of the unit tool nonlinear synthesis method, enabling more accurate cutting force models for complex blade bits.
WangJL (1994) studied chip evacuation and applied the unit tool nonlinear synthesis method to build a cutting force model for any blade bit based on an empirical bevel cutting force model. Beyond basic geometry, many factors in the drilling process influence drilling forces. ChandrasekharanV et al. (1996) considered manufacturing and sharpening errors, such as the contour of the two main edges, radius error, and axial deflection, to develop a complete three-dimensional cutting force model for conical drill bits, which was later extended to predict forces for any shape drill bit, including group drills.
SriramR developed a model for predicting radial force while accounting for the effects of drill sharpening and installation errors. In 2001, GongYP and EhmannK created a micro-hole drill model that incorporated the geometry of the drill bit, sharpening and mounting errors, and the impact of bit deflection on dynamic cutting thickness and area of the main and chisel edges. These advancements demonstrate the ongoing effort to improve accuracy and adaptability in drilling force modeling across a wide range of applications.
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