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Procedia CIRP 13 (2014) 103 107

2nd CIRP Conference on Surface Integrity (CSI)

Effect of the cutting edge preparation on the surface integrity after

dry drilling
Fernando Moreira Bordina, Rodrigo Panosso Zeilmanna*
a
Center of Exact Sciences and Technology, University of Caxias do Sul, Francisco Getlio Vargas, 1130, Caxias do Sul, 95070-560, Brazil.
* Corresponding author. Tel.: +55-54-3218-2168.E-mail address: rpzeilma@ucs.br.

Abstract

Nowadays, cutting edge preparation is a widely applied tool improvement method, especially when concerns tools life. However,
the effects of the tool treatments on the generated hole surface are still an ongoing investigation. The machined hole is subject to
severe contact with the tool, in particular the drill corner and guide, providing an increase of friction and thus, heat generation.
Consequently, the surface integrity suffers several alterations. Therefore, this study aims to understand the effect of the cutting edge
preparation on the surface integrity of holes. Experiments performed with carbide tools, coated with TiAlN and three configurations
of tools (sharpened, polished with abrasive brushes and treated with drag finishing surface treatment) during dry drilling, showed
that the tool condition has an important effect on the surface roughness, temperature and subsurface plastic deformation.

2014
2014 The
The Authors.
Authors. Published
Publishedby
byElsevier B.V.Open access under CC BY-NC-ND license.
ElsevierB.V.
Selection and
Selection andpeer-review
peer-reviewunder responsibility
under of The
responsibility International
of The Scientific
International Committee
Scientific of the 2nd
Committee Conference
of the on Surfaceon
2nd Conference Integrity
Surface
in the person of the Conference Chair Prof Dragos Axinte dragos.axinte@nottingham.ac.uk
Integrity in the person of the Conference Chair Prof Dragos Axinte dragos.axinte@nottingham.ac.uk

Keywords: Drilling; Roughness; Plastic deformation.

1. Introduction defects and reinforcement of the edge, in order to

The machining processes, largely applied in the
production industry, are highlighted in most segments of
modern manufactory. The high competitiveness of the
globalized market leads to obtain as main requirements,
low costs and lesser process times. However, the
conditions in which the tool is subjected render the
process each time more severe, reducing the tool life.
The necessity of tool performance improvement,
aiming to supply the market necessity, directs the tool
manufacturers to a new trend: improvement of standard
tools. Techniques already disseminated, such as coating
application and tool geometry modification, aids to
obtain tools with higher durability. Inserted in this view
is the cutting edge and surface preparation of tools [1].
Even with the advance of the production technology,
the presence of defects in the tool manufacturing was not
completely eliminated [2]. Cutting edge preparations
consists in generating controlled edge geometry and
modifies the micro topography, along with the roughness
and texture of the tool surfaces (flank and rake face) in
the wedge. The consequence is the reduction of the
improve the performance, reliability of the cutting tool
and machined surface quality [1,3].
Honed/chamfered cutting edge can alter the
fundamental aspects of the cutting mechanics, which in
turn affects the chip formation and flow, machining
forces, heat and temperature distribution, wear of tools
and surface integrity of the machined component [4-8].
Surface integrity describes the alterations produced in
the superficial layer during the machining, including the
effects on the material properties and the performance of
surface during service, especially structural components
subject to high static and dynamic strains [9].
Some studies evaluated the effect of the honed edge
on the roughness after drilling. Biermann et al. (2012)
observed that the roughness increases with the
increasing tool edge radius [8]. Risse (2006) observed, in
comparison between honed and non-honed tools, that the
roughness was similar between the tested conditions [7].
In another study, Biermann and Terwey (2008), during
drilling of an AISI 1045 steel with carbide tools
presenting different levels of edge radius (without,
slightly and severely honed), observed that the peaks of

2212-8271 2014 The Authors. Published by Elsevier B.V. Open access under CC BY-NC-ND license.
Selection and peer-review under responsibility of The International Scientific Committee of the 2nd Conference on Surface Integrity in the person
of the Conference Chair Prof Dragos Axinte dragos.axinte@nottingham.ac.uk
doi:10.1016/j.procir.2014.04.018
104 Fernando Moreira Bordin and Rodrigo Panosso Zeilmann / Procedia CIRP 13 (2014) 103 107

roughness were superior for tools without honing [10]. Table 1. Roughness values on the tool face for the different conditions.
Contrary to the previous authors, Cheung et al. (2008)
observed during drilling of DIN 40CrMnNiMo8-6-4 Ra [m] Rz [m] Ry [m]
steel with high-speed-steel tools and different levels of Mean 0.19 1.37 1.72
edge radius (without, 24 and 48 m), that the mean SH
Std. Dev. 0.06 0.40 0.50
roughness was lower for the intermediate condition, and Mean 0.15 1.23 1.59
with similar values for the without and higher honed DF
Std. Dev. 0.04 0.18 0.26
edge [11].
Mean 0.14 0.91 1.14
Concerning subsurface alterations, Risse (2006) POL
Std. Dev. 0.04 0.22 0.29
during drilling of AISI 1045 steel, observed no plastic
deformation along the longitudinal direction of the hole,
SH DF POL
for tools with and without honed edge [7].
In this context, this study aims to evaluate the effect
of the tool cutting edge and surface preparation, after dry
drilling, on the surface integrity of the hole. 5 m 5 m 5 m

2. Materials and Methods Figure 1. Rake face texture for the different tool conditions.

The experimental tests were performed on a CNC The tool was also characterized in terms of cutting
machining center, Dyna Myte DM 4500, power of 7.5 edge modification, through the detailed view of tool
kW and maximum rotation on the spindle of 6000 rpm. corner, from the rake face and guide, illustrated on
The machined material was a mould and die steel, AISI figure 2.
P20. The workpiece was fixed parallel to the machine
SH DF POL
table; with dimensions of 120 x 80 x 30 mm.
As machining conditions it was used a cutting speed
vc of 40 m/min and feed f of 0.10 mm/rev. The hole
depth was three times the tool diameter, 25.5mm. The 0.02 mm 0.02 mm 0.02 mm

distance between holes was also three times the diameter

of the tool, 25.5 mm.
Tungsten carbide drills coated with TiAlN, diameter
of 8.5 mm, K30 grade, and geometries according to DIN 0.02 mm 0.02 mm 0.02 mm

6537K, were used as cutting tools. Three conditions of

tools were used: sharpened (SH), polished with abrasive
brushes (POL) and drag finished (DF).
The polishing process was conducted with the help of
a sponge, provided with abrasive filaments. The sponge
was fixed on a manual pneumatic mini-grinder, working
with a rotation of 25,000 rpm. While rotating the drill,
the fixed mini-grinder sponge acted on the flutes,
promoting the polishing of the rake surface.
The drag finishing process was carried out in an
OTEC machine, DF-3. The tools were submersed on an
abrasive media, containing several grains, specific for
tool honing. The process time was 5 minutes in
clockwise rotation and 5 minutes in counter-clockwise
rotation.
Tools characterization was performed in terms of rake
face roughness and texture. Roughness measures were
carried by a Mitutoyo SJ-301 roughness tester, with cut-
off of 0.25 mm. Table 1 references the measured values
for the tool roughness and figure 1 illustrates the
different textures for the tools.
Figure 2. Detailed view of the tool corner by SEM.
Surface integrity of the machined hole was
characterized in terms of roughness Ra, Rz and Ry,
measured, at the beginning of the hole, assessed with a
cut-off of 0.8 mm, two measures each hole (90 and
270).
For the subsurface characterization, the machined
hole microstructure was assessed through the sectioning
of the hole, at the beginning, and evaluating its border
deformation, evaluating three parameters: mean affected
layer ALa, maximum mean affected layer ALz and
maximum affected layer ALy, at three regions each hole.
As auxiliary evaluation, it was measured the
temperature behavior on the hole wall, also at the
beginning. Thermocouples type K, embedded on the
workpiece, distant 0.1 mm of the hole wall, were fixed
with a split pin, which ensured the thermocouple
fixation. The temperature was captured with the help of
a A/D conditioner, Scanner 5100, brand Vishay Micro-
Measurements, 15 bits resolution, sampling rate of 10
Hz.
 Fernando Moreira Bordin and Rodrigo Panosso Zeilmann / Procedia CIRP 13 (2014) 103 107
3. Results and discussion
3.1. Roughness and texture
The surface quality is an important aspect that can
alter the tribology interaction when considering the
applications of the hole of a component. Usually, it is
characterized by the roughness and texture, which
evidences the material removal during drilling. Figure 3
illustrates the measured and obtained surface.
25
Roughness [m]
Ra
20
Rz
15
Ry
10
5
0 The highest temperatures were observed for the
SH POL DF
2 mm 2 mm 2 mm
Figure 3. Hole wall: roughness values (a) and texture (b) for the three
tested conditions.
The highest roughness values were measured for the
sharpened condition, followed by the polished and drag
finished tools. One hypotheses is related to the
interaction between the chip and the hole wall, due to the
chip flow difficulty. Lower rake face peak roughness for
the tool in condition POL (Ry = 1.14 m) aids the chip
flow, impacting in lesser interaction with the hole wall
when compared to higher roughness, SH (Ry = 1.72 m)
DF (Ry = 1.59 m).
Also, the tool guide texture may affect the generated
hole wall. Pashovkin (2009) related the surface
generation during drilling with the contact effect of the
guide with the hole wall. The fabrication marks on the
tool guide were factors that influenced the roughness [9].
Since the DF and POL conditions presented a smoother
guide surface and lesser contact area, the generated
surface presented lesser roughness and texture.
In agreement, Biermann and Terwey (2008) observed
during dry drilling of an AISI 1045 with tungsten
carbide tools with and without edge treatment, which the
corners with severe honing impacted on lesser roughness
values than corners with slight or no honing [10].
3.2. Temperature
The temperature measured during drilling can support
the understanding of the involved phenomenon during
cutting, and the comprehension of the cutting mechanics
105
and surface generation. Thereby, figure 4 presents the
average maximum and behavior of the temperature,
obtained for each tool condition.
100
DF
SH
POL
80
Tambb SH
DF
Temperature [C]
60 POL
40
20
0
0 1 2 3 4 5 6 7 8 9 10 Maximum
Time [s] temperature
Figure 4. Behavior and maximum temperature during drilling.
sharpened and drag finished condition, whereas the
polished obtained lesser values. This behavior could be
associated to the less heat generation due to the lower
chip friction between tool and workpiece. With the flow
of chip benefited in the POL condition, there is a lower
interaction between the removed material and the hole
wall, which in turn corroborates with the
texture/roughness hypotheses concerning the chip flow.
The temperature behavior showed higher values for
the DF and SH conditions, with a linear temperature
increase as the chip flowed. The POL condition showed
a constant temperature behavior, with lesser temperature
increase in comparison with the other conditions.
Contrary to the expected behavior, the temperatures
after tool passage tended to increase. The heat
generation caused by chip/hole wall friction can be
comparable to the cutting edge heat generation,
according to Tai et al. (2012) [13].
Zhou and Wang (2012) stated that the plastic
deformation of the material, and consequently, energy in
form of heat, increases with cutting edge radius. There is
an increase on the contact areas between tool/chip and
tool/workpiece, which causes an increase of the heat
transport area [14].
3.3. Affected layer
To better understand the alterations caused by the
drilling process, it was characterized the subsurface
affected layer. This layer is commonly evaluated by the
plastic deformation of the subsurface, locally observed
by the material drag on the hole boundary. Figure 5
illustrates the obtained affected values and micrographic
image.
The conditions SH and DF presented highest values
for the affected layer, whereas the POL condition
106 Fernando Moreira Bordin and Rodrigo Panosso Zeilmann / Procedia CIRP 13 (2014) 103 107

presented a trend of reducing the affected layer 4. Conclusions

thickness. This behavior could be associated with the
hole wall temperature. As the workpiece heat increases, Higher roughness values were observed for the
the materials shear strength decreases, benefiting the sharpened tool, whereas the other conditions presented
plastic deformation [15, 16]. lesser values, associated to the better interaction between
tool guide/hole wall and tool flute/chip flow. Minimum
50 100 temperature values were obtained for the polished tool.
ALa This behavior can be also associated with the interaction
Temp.
Affected layer [m]

40 ALz 80
between tool flute/chip flow.

Temperature [C]
ALy
30 60 The measured affected layer values were similar to all
40
conditions. However, it was observed a trend of slight
20
affected layer thickness reduction for the polished
10 20 condition, possibly related to the temperature.
0 0
SH POL DF

Acknowledgements
Figure 5. Affected layer for the different tool conditions.
The authors thank Prof. Ms. Gerson L. Nicola for his
Contrary to this study, Risse (2006) observed no help during experimental procedure and University of
alteration of the subsurface integrity when machining Caxias do Sul for the financial support.
with tools with and without edge rounding. The author
considered only the longitudinal orientation of the hole
[7]. However, during the drilling process, the cutting and References
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