Prediction of the cutting forces generated in the drilling of carbon-fibre-reinforced plastic composites using a twist drill

The cutting force is regarded as the main factor that influences the quality of the hole created in the drilling of carbon-fibre-reinforced plastic composites. This paper proposes a model for the prediction of the thrust force and torque generated in the drilling of composite materials using a twist drill. In the model, contact theory is applied to the chisel edge cutting zone and oblique cutting is considered in the cutting lips cutting zone that is considered to have three distinct deformation regions. The model takes into account the spindle speed, feed rate, drill diameter, point angle, nose radius, rake angle of the chisel edge, web thickness, and fibre orientation. The cutting forces predicted by this model are in satisfactory agreement with experimental results and thus it is concluded that the proposed model can be used to optimize the cutting parameters and tool geometries in the drilling of composites.