This study investigates the chip clogging phenomenon which occurs in dry drilling of aluminum alloys and composites, and yet, is seemingly critical to the drill life. This issue must be resolved in order to facilitate dry drilling. A highspeed dry drilling test using common twist drills was conducted with the workpiece temperature pre-heated to a wide range, room to 265 °C. The drills after testing were then examined in terms of aluminum residue that strongly adheres with the flute surfaces. A possible transition temperature range that may result in severe aluminum build-up and chip clogging was identified under the tested condition.

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