Controlling drilling temperature and thrust forces play a significant role in reducing tool wear and improving machining efficiency. In this work, drilling experiments are set up to measure flank surface temperature via thermocouple sensor wires passed through the coolant holes of 10mm twist drill and brazed to the drill flank surface. The testing setup is an inverted drilling jig where the workpiece (Aluminum 6061-T6 rod) is chucked into the spindle of a vertical machining center. Thrust forces are co-measured using Kistler type 3-component plate dynamometer attached to the table. A design of experiment (DOE) using JMP-SAS/STAT® was adopted for selecting combinations of cutting speed and feed values that cover a wide range.

Drilling temperature rise and thrust forces are found to correlate with cutting conditions of feed (f), maximum cutting speed (V), and drilling depth (Dp). Nonlinear regression analysis produced correlating equations of flank temperature rise and thrust forces to conditions and follow a mechanistic power law of the form a1fa2Va3Dpa4 where a1, a2, a3 and a4 are identified via regression fitting.

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