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Materials Today: Proceedings 16 (2019) 824–831 www.materialstoday.com/proceedings

ICAMMAS -2017
Investigation the Effect of Point Angle While Drilling Titanium
G.Yuvaraj a, Fannan C.B.Va, b, c, A.P.Junaidhb, V.Aakashc
a
KCG college of Technology, Chennai and 600097, India
b
Indian Institute of Technology, Madras and 600036, India
c
KPR Institute of Engineering and Technology, Coimbatore and 641047, India
d
KPR Institute of Engineering and Technology, Coimbatore and 641047, India

Abstract

Titanium is classified as difficult to cut material due its high chemical affinity, low thermal conductivity, high hot
hardness etc. In this paper the influence of point angle using Titanium- Ti-6Al-4V is studied. For that the finite element
modelling of the drilling is carried with Johnson cook flow stress modelling with different operating parameters and different
point angled tools. For experimental validation a 4mm solid carbide drill with TiAlN coating is used as the tool material with
three different point angles to make a through hole using a vertical machining centre. The burr formed for different tool and
parameters were observed. The chip formed during the machine was collected and the effect of point angle on the chip shape has
0
studied. A drill cap was formed while using tool with 140 point angle tool. During finite element modelling it is found that the
0
stress at starting of the cutting edge is maximum as opposed to tool tip for 118 pointed angle tool.
© 2019 Published by Elsevier Ltd.
Selection and/or Peer-review under responsibility of International Conference on Advances in Materials, Manufacturing and Applied Sciences.

Keywords: Drilling, Titanium; Point angle, Burr; cutting forces; FEM, Carbide tool

Drilling is the machining process which makes the hole by using multi point cutting tool, depends upon the
material of cutting tool, the feed rate and depth of cut is decided. In order to improve the effect of drilling
parameters, preferably used titanium for good hot hardness, high strength and low thermal conductivity. Based upon
the tool point of contact, the chip flow and cone shaped formation has been performed. Yingying wei et.al. [1] had
done the experimental study of carbon fiber reinforced titanium alloy investigated about drilling forces, drilling
chips of two different tools such as tungsten carbide twist drill and chemical deposition diamond coated drill, it
indicated the results feed rate and drill quality have connection which improves the delamination drill chips. (fcc)
structure is very tough and ductile down to absolute zero.
Jaromir audy [2] studied about twist drill geometry and analyzed in two different twist drills such as general purpose
drill and deep hole jobber drills, these drills have their point geometry which discussed about the rake angle
distribution and thrust force analysis.

G.Yuvaraj et.al [3] studied about the properties of drilling behavior of sisal epoxy reinforced composites and proved
increasing of sisal which strengthened the plate. S.Madhavan et.al.[3] investigated the drilling properties of CFRP
using HSS tool, Solid carbide, polycrystalline diamond tool and it proved continuous chips produced using HSS
toolK.V.Santha Kumari et.al. [4] experimented the tool cutting angle which influences the effective machining in

* Corresponding author. Tel.: +91-9443919169 .

E-mail address: profjaya@gmail.com

2214-7853 © 2019 Published by Elsevier Ltd.

Selection and/or Peer-review under responsibility of International Conference on Advances in Materials, Manufacturing and Applied Sciences.
 G. Yuvaraj et al. / Materials Today: Proceedings 16 (2019) 824–831 825

feed rate, cutting edge. Mohd Azuwan Moinsea et.al [5] analyzed three drill angle of twist drill 85º,118º,135ºis used
to drill in hybrid composites, finally the results shows small drill angle and feed rate reduced the damage of drill
entrance and exit. Satosi [6] investigated the relief angle, helix angle and torque of the twist drills are investigated.
Norberto feito et.al [7] investigated the effect of drill geometry with surface quality effects and influence of drilling
geometry in CFRP. Uwe diesel et.al [8] gave the experimental results, the quality of drilling was increased when the
drill angle is greater than 180º.
Shreemoy Kumar Nayak.et.al. [9] Analyzed the ISO P30 grade uncoated cemented carbide cutting tool of cutting
force, surface roughness characteristics. Groover MP [10] investigated the buildup edge formation on the tool when
it made to contact on work piece at small running speed of 140 rpm. Chromium, molybdenum and other alloying
metals added also decrease machinability of austenitic stainless steels.. Korkut et al. [11] investigated the properties
of AISI 304 steel having high strength, able to withstand the thermal heat distribution which increases the cutting
force and feed rate. Ibrahim Ciftci [12] studied the single point tool machining characteristics of turning operations
made by AISI 304 and AISI 316 grade austenitic stainless steel specimens by using TiC/TiCN/TiN and TiCN/TiC.
Swapnagandha et al. [13] studied the effect of chip – tool interface by adding titanium with aluminum alloy
operated at the speed of 1270 rpm in drilling operation, which results in improvement of surface finish. Fernández-
Abia et al. [14] studied about the Behaviour of PVD coatings in the turning of austenitic stainless steels (AlTiSiN,
AlCrSiN, AlTiN and TiAlCrN) and measured tool wear, cutting forces. Jianxin et al. [15] investigated the fatigue
strength and by adding Cr12Mn5Ni4Mo3Al it improves the hardening and corrosion withstand capacity. Hence the
present study is focused on understanding the characteristics of Ti-6Al-4V under the drilling operation, which
influences the thrust force, burr formation and the exit hole diameter in three different angles in which compare the
experimental values with FEM using Deform 3D –Software.

2. FINITE ELEMENT MODELING OF THE PROCESS

DEFORM-3D software is used for FEM. It uses lagrangian model with automatic remeshing capability. Ti-
6Al-4V is selected at the work piece material and tungsten carbide as the tool material. The tool is specified as a
rigid body and work piece as a deformable one.

Fig 1. Tool workpiece assembly and formation of chip during the FEM simulation
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In the present wok Johnson-Cook law to model flow stress is used for the plastic flow behavior of the work piece
Table 2 shows the Johnson Cook parameters of the work piece.

2.1. Modelling of work piece

The work piece is made in a cylindrical shape with a diameter of 60mm and a depth of 10mm. The degree of
freedom for the work piece around the periphery is restricted in all axes and no restriction over top and bottom
surface so that the material removal will occur on top and bottom. The automatic meshing of the work piece is done
with 9489 elements.

2.2 Modelling of tool

A Tool with 4mm diameter with helix angle 300, web thickness 1.1mm, margin 0.2mm and clearance 0.1mm is
made with three point angles 118º, 130º and 140º.the tool is given 2 degrees of freedom, translation and rotation
along the z axis. Tool is also given with automatic meshing with 7364 elements in tetrahedron shape. Figure 1 show
the tool wok piece assembly and formation of chip during the simulation.

3. EXPERIMENTAL PROCEDURE

An alpha-beta Titanium alloy Ti-6Al-4V was selected as the work piece. The Titanium piece was a size of 56
x56 x10mm (L xW xT) and the centre to centre between the holes were 8mm. The work piece is arranged in such a
way that there is no support at the bottom so the burr will be formed as shown in figure2 & figure 3. A 4mm TiAlN
coated carbide tool is used for the drilling with three point angles and same helix. A VMC of Ace manufacturing
System make was used for the machining purpose. The machine has a maximum spindle speed of 6000 RPM. A
Kistler made multi component piezo electric dynamometer was used for the measurement of the thrust force, user
friendly Dyno ware software is used to take the output of the dynamometer.

Fig 2. AMS DTC 300 Vertical machining Centre Fig 3. Arrangement of work piece

Feed and speed are the two parameters which were varied during the machining. The depth of cut is given as 13mm to
make sure that the tool tip will pass completely through the work piece even though the work piece height or depth is 10
mm. four stages of speed and feed are selected for the machining and complete full factorial experiments is done. A total
of 48 experiments are done, a count of 16 for each tool with 3 tools. All the machining was done in dry cutting i.e., no
 G. Yuvaraj et al. / Materials Today: Proceedings 16 (2019) 824–831 827

coolant was used. Bottom of the work piece is held freely, without any support as shown in figure 3. The dynamometer is
connected to a charge amplifier then to a computer to read the force values produces during the machining. A Zeiss made
stereo microscope was used to obtain the images of the tool, work piece and the chip.
Chemical composition of Work piece is shown in the table 1. For manufacturing the work piece, we have to add the
proportions. The chemical composition is analyzed by using EDAX analysis and their image is seen in fig 4.

Element Wt.%

AlK 07.39

TiK 89.21

VK 03.40

Matrix Correction

Table 1. Chemical Composition of Work piece

Fig 4. Edax Analysis of the work piece

4. TESTS AND RESULTS

4.1. Thrust force

Filtering and signal drift compensation was applied to these signals to get the output. The other
components of force were negligibly small compared to that of the thrust force, so those components were
omitted. The variation in the thrust force for all the tools with point angles 118º, 140º and 130º are
experimented. The comparison of the thrust force from FEA and experimentation. It can be seen that the
FEA results almost accepts with the experimental validation. The thrust force is increasing with feed
irrespective of speed and the point angle. As the feed increases the volume of the material to be removed
increases for each revolution, since the drill bit has to advance a higher distance for each revolution. When
the feed increases the tool has to make extra effort, which is reflected as increase in thrust force.

Figure 7 shows the variation of the thrust force with respect to the point angle. It is identified that the
thrust force for the 140º point angles tool is the greater, because as the point angle increase the length of
the cutting edge will decreases well as the support at the periphery of the point will be less. Figure 4.
Shows a small change in force at the periphery will be recorded as high.
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The effect of cutting speed on the thrust force can be deduced shown in table 2. It is expected to have a
decrease in thrust force with increase in speed. This is due to the thermal softening of the work piece at higher
speeds. Initially there is a decline in thrust force with increase in speed, and at higher speeds it is also visible that the
cutting speed is increasing.
Table 2. Thrust force variation for different feed and speed using different tool

Thrust Force Fz (N)

Sl Speed Feed Tool with point angle Tool with point angle Tool with point angle
No. (RPM) (mm/rev) 1180 1400 1300

Experimental FEA Experimental FEA Experimental FEA

1 2500 0.01 157.7 140.9 221.3 200.48 195.2 180.48

2 2500 0.015 219.4 210.4 269.1 260.29 244.25 220.6

3 2500 0.02 242 243.7 302.2 287.14 273.1 234.6

4 2500 0.025 266.8 308.1 329.2 320.18 297.5 254.14

5 3000 0.01 189.4 165.6 217.5 198.44 200.54 200.98

6 3000 0.015 217 208.6 265.3 260.48 243.58 218.17

7 3000 0.02 244.5 241.5 294.4 278.55 267.17 234.86

8 3000 0.025 270.9 248.8 322.1 324.1 292.5 310.93

9 3500 0.01 174.4 164.1 195.2 184.01 182.8 180.81

10 3500 0.015 209.2 201.5 240.8 220.4 223.5 217.19

11 3500 0.02 232.9 210.6 272 250.5 254.2 210.67

12 3500 0.025 250.5 243.8 299.4 315.94 272.9 240.14

13 4000 0.01 196.2 189.4 203.4 201.52 200.1 187.97

14 4000 0.015 214.4 198.2 238.3 214.29 224.35 211.58

4.2 Burr formation

From the experimentation it is seen that the drill burr was formed for tools with point angle 118º and 130º and for
tool with point angle 140º drill cap was formed without any significant burr. For Tool with point angle 118º it is also
seen that at higher speed and feed there is curling back of chip. At higher speed the cutting temperature will be very
high which passes on to the chip. So the inner side of the chip will at high temperature compared to that of the outer
side of the chip, so thermal expansion at the inner side will be higher than that of the outer side, thus chip will curl
inside out. The low thermal conductivity of the Titanium favours this process thus coiled burr is formed at the higher
speed.During drilling the material just before the tool tip will be plastically deforming. It will forms in a shape
negative to the drill bit forms in the shape of a cap. So when the drill bit reaches the exit of the hole there will be
three places where the strength will be least, one at the tool tip and the other at the periphery of the hole. Depends
upon the cutting force depth of hole varies is shown in fig 5.
 G. Yuvaraj et al. / Materials Today: Proceedings 16 (2019) 824–831 829

Fig 5. Variation of thrust force in different angle with respect to depth of hole

4.3 Exit hole diameter

The radius of the hole is measured using a stereo microscope and its associated software named Axio vision.
Circle is fit along the boundary of the hole to get the radius is shown in fig 6. The radii increase with both feed and
speed. Increase of radii with feed might be due to the increased thrust force in the tool which might cause the
vibration of the tool. But this change is comparatively small compared with the effect of speed.As the speed
increases a drastic change in the exit radii can be noticed in fig 7.

Fig 6. Drill burr formation for tool point angle 118º Fig 7.Drill cap formation when drilling point angle 140º
830 G. Yuvaraj et al. / Materials Today: Proceedings 16 (2019) 824–831

Fig 8. Variation of exit hole radius with Speed and feed for tool 2

Fig 8. Shows depth of hole increases with the speed by using the tool number 2 with the function of thrust force.
Hence the radii value decreases with the decrease in feed rate and the increase in speed.
5. CONCLUSION

This report is focused on dry drilling of Titanium Ti-6Al-4V alloy, studying thrust force variation, burr
formation, exit hole diameter. Three types of tools of carbide were used with different point angles 118º, 140º and
130º each of diameter 4mm was used to make a through hole in the work piece. The lowest thrust force was
recorded at 3500 RPM and was found to be higher at all other RPM. The thrust force was found to be increasing
with the increase in point angle as the tool became blunter as the point angle increased. The burr formed during the
machining found to be in a rolled back inside out position at higher speed due to the increase in temperature and the
low thermal conductivity of the Titanium. A long continuous chip was formed in all the cases with two distinct
regions. The exit hole diameter was found to be increasing with speed, but it didn’t shows any particular variation
with the feed. The built up edge formation was found to be prominent in the tools with low point angle. The thrust
forces for higher cutting point angles were higher but the variation of the thrust force through the hole was found to
be minimums for higher point angles. Implies for higher point angles the vibration of the tool will be less and can be
used for deep hole drilling purposes.
Hence the variation of the thrust force through the hole and there is a sudden rise in the force at the initial contact of
the tool with work piece is more for the 120º pointed angle tool than the rest.
The radii increase with both feed and speed. Increase of radii with feed might be due to the increased thrust force in
the tool which might cause the vibration of the tool was done in the angle of 130º.
From the experimentation it is seen that the drill burr was formed for tool with point angle 118º at higher speed and
feed there is curling back of chip.
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