The three dimensional (3D) finite element modeling (FEM) and experimental validation of drilling are presented. The Third Wave AdvantEdge machining simulation software is applied for the FEM. It includes fully adaptive unstructured mesh generation, thermo-mechanically coupling, deformable tool-chip-workpiece contact, interfacial heat transfer across the tool-chip boundary, and constitutive models appropriate for process conditions and finite deformation analyses. The workpiece is modeled with a predrilled cone-shape blind hole to enable the early full-engagement of the whole drill point region to reduce the simulation time. Drilling experiments are conducted on the Ti-6Al-4V using a twist drill geometry. The calculated cutting force and torque are compared with the results of experiments with good agreement. Effects of process parameters on the stress and temperature distributions of the drill and workpiece are investigated in detail using the FEM.

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