ARTICLE IN PRESS

International Journal of Machine Tools & Manufacture 49 (2009) 81–88

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International Journal of Machine Tools & Manufacture

journal homepage: www.elsevier.com/locate/ijmactool

Friction drilling of austenitic stainless steel by uncoated and PVD AlCrN- and
TiAlN-coated tungsten carbide tools
Shin Min Lee a, Han Ming Chow b, Fuang Yuan Huang a, Biing Hwa Yan a,
a
Department of Mechanical Engineering, National Central University, Chung-Li 32001, Taiwan
b
Department of Mechanical Engineering, Nankai Institute of Technology, Nantou, Taiwan

a r t i c l e in fo abstract

Article history: Friction drilling utilizes the heat generated from the friction between the tool and the thin workpiece to
Received 4 January 2008 form a bush for fixtures such as screw threads in plastic deformation process. This process produces no
Received in revised form chip, shortens the time required for hole-making and incurs less tool wear, thus lengthening the service
23 July 2008
life of the drill. In this study, tungsten carbide drills with and without coating were employed to make
Accepted 24 July 2008
holes in AISI 304 stainless steel, which is known to have high ductility, low thermal conductivity and
Available online 5 August 2008
great hardness. TiAIN and AlCrN were coated onto the drill surface by physical vapor deposition (PVD).
Keywords: Performance of coated and uncoated cutting tools was examined for drillings made under different
Friction drill spindle speeds. Changes in relationship between drill surface temperature, tool wear and axial thrust
Chipless machining
force during machining were also explored. Experimental results reveal that lubricating effect of the
Dry drilling
coating and low thermal conductivity of AlCrN caused AlCrN-coated drill to produce the highest surface
Stainless steel
temperature but the lowest axial thrust force with the least tool wear. However, the difference in
performance between coated and uncoated drills diminished with increase in number of holes drilled.
Crown Copyright & 2008 Published by Elsevier Ltd. All rights reserved.

1. Introduction Previous research on approaches to hole-making focuses

Friction drilling is a non-traditional hole-making method that
utilizes the heat generated from the friction between a rotating
conical tool and the workpiece. Mostly used on thin workpieces,
friction drilling forms a feature for fixtures such as screw threads,
a process of plastic deformation. The tool is often made of
tungsten carbide and rotates at high speed, which produces
friction heat [1–3]. The frictional heat energy thus produced
softens and penetrates the workpiece. The process forms a
bushing in situ and is clean and chipless. This chipless machining
process has the advantages of reducing the time required for
drilling and incurring less tool wear, thus lengthening the service
life of the drill. The added height of the bushing formed can
lengthen the threaded portion of the hole, and consequently
increase the fastener clamp load for joining thin sheet metal. On
the other hand, traditional wet drilling requires cutting fluid to be
added during machining. However, cutting fluid is hazardous to
both human health and environment. Hence, dry drilling that
requires no addition of cutting fluid is gradually replacing wet-
drilling processes [4], and friction drilling can meet the need for
dry machining.
 Corresponding author. Tel.: +886 3 426 7353; fax: +886 3 425 4501.
E-mail address: bhyen@cc.ncu.edu.tw (B.H. Yan).
mainly on twist drills. However, tool life of twist drills is much
shortened due to rapid tool wear and they even break when
drilling hard-to-be-cut materials. Such a problem is particularly
serious when processing austenitic stainless steel with twist
drills. It is because austenitic stainless steel has great toughness,
low thermal conductivity and high work-hardening coefficient [5].
However, austenitic stainless steel is widely used in aircraft,
medical equipment and automobiles due to its high resistance to
corrosion and wear. In view of the difficulty involved in drilling
stainless steel, much effort has been devoted to exploring the best
material and ideal shape of the drilling tool as well as the most
optimal processing parameters.
In the above-mentioned research, most of the cutting tools
studied were coated with ceramic. Related literature [6,7] also
reveals that sintered carbide cutting tool coated with physical
vapor deposition (PVD) technology offered proven performance
advantages over their counterparts coated with chemical vapor
deposition (CVD). Sharif and Rahim [8] pointed out that the
presence of a coating could offer solid lubrication during
processing, thus reducing tool wear. Chen and Liu [9] found that
coated twist drills showed good cutting performance in making
holes in stainless steel. Fox-Rabinovich et al. [10] compared the
wear resistance of cutting tools with TiAIN and AlCrN coating
under elevated temperatures and found that AlCrN-coated cutting
tools had better wear resistance and thus longer tool life. Kalss

0890-6955/$ - see front matter Crown Copyright & 2008 Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2008.07.012
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82 S.M. Lee et al. / International Journal of Machine Tools & Manufacture 49 (2009) 81–88

et al. [11] stated clearly in their research that AlCrN-coated cutting

tools suffered less wear than TiAlN-coated ones because the
thermal conductivity of AlCrN is lower than that of TiAlN.
However, the oxidation resistance of AlCrN coating decreased
with increase in processing temperature. In the study of Endrino
et al. [12], stamping and forging tools with AlCrN coating could
enhance the degree of oxidation at the tool–workpiece interface.
Miller et al. [1,2] applied friction drilling to machining low-
carbon steel as well as aluminum and magnesium alloys, and
explored experimentally the relationship between axial thrust
force and torque under different spindle speeds and feed rates.
However, the effects of tool coating and drilling temperature have
not been studied. Lee et al. [13] have successfully applied friction
drilling to IN-713LC cast superalloy and assessed the material
properties after machining including hole roundness as well as
surface roughness and hardness of hole-wall. Nevertheless, there
has been no study yet on friction drilling of difficult-to-cut
materials, such as stainless steel. To make up for such deficiency, Fig. 1. Experimental setup of friction drilling.
this research was conducted with two objectives. First, it aimed to
examine and compare the performance of tungsten carbide drills
with and without AlCrN and TiAIN coating under different spindle Table 3
speeds. Second, by applying friction drilling to AISI 304, a type of Composition and mechanical properties of tungsten carbide
stainless steel widely used in industries, this research also
Composition WC 87%, Co 12%, others 1%
explored the changes in relationship between surface temperature Grain size Ultrafine (0.4–0.6 mm)
of drills, tool wear and axial thrust force during machining. The Density 14.2 g/cm3
results thus obtained can provide new insights into application of Hardness 1680 HV30 92.7 HRA
friction drilling to hole-making in stainless steel. Transverse rupture stress 4300 N/mm 635000 PSI
Compressive strength 6.5 kN/mm2

2. Experimental setup and procedures

A sheet of AISI 304 stainless steel was cut into workpieces of

30  30  2 mm. Table 1 gives the chemical composition of the
AISI 304 stainless steel and Table 2 compares the thermal
conductivity of different materials.
Fig. 1 is a schematic diagram of the experimental setup for
friction drilling. A CNC machine center (Fulland FMC-1000) was
employed in the experiments to minimize the impact of external
interference on the quality of drilling.
The sintered tungsten carbide bar (RX12UF) was purchased Fig. 2. Design of friction drill.
from Hartmetall Company, Germany. Table 3 displays the

Table 1 Table 4
Chemical composition of AISI 304 stainless steel Machining conditions of thermal friction drilling

Chemical element Content (%) Factors Parameters

C 0.08 Spindle speed (rpm) 2400, 3600, 4800, 6000

Si 1.0 Feed rate (mm/min) 100
Mn 2.0 Diameter of drill (mm) 8
P 0.045 Types of drill Uncoated (UC), TiAlN-coated (TC), AlCrN-coated (AC)
S 0.03
Cr 18–20
Ni 8–12
composition and mechanical properties of tungsten carbide. The
bar was machined by a diamond grinder to the required shape and
size. As shown in Fig. 2, the drill was 8 mm in diameter.
Table 2
Thermal conductivity of materials Table 4 lists the machining condition of thermal friction
drilling used in this study. As can be seen, there are three different
Material W/m K kinds of drills: uncoated, TiAlN-coated and AlCrN-coated. The
coating was 4.2 mm thick.
Aluminum alloys 210
Tungsten carbide 84
Fig. 3 illustrates the steps involved in friction drilling. In brief,
Carbon steel 37 the friction drill comes into initial contact with the workpiece and
AISI 304 stainless steel 21 then penetrates into it at great axial thrust force and high spindle
Nickel-based superalloys 11.2 speed (Step 1). The friction force on the tool–workpiece interface
Ti-6Al-4V 7.3
produces heat and melting of the work-material occurs. Further
Glass 0.8
drilling pushes up the molten metal (Step 2). Finally, the friction
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S.M. Lee et al. / International Journal of Machine Tools & Manufacture 49 (2009) 81–88
Fig. 3. Steps involved in friction drilling.
Fig. 4. Images of (a) overview and (b) cross-section of friction-drilled hole on AISI
304 stainless steel.
drill breaks into the workpiece, making a hole, through which the
molten metal is pushed down (Step 3). The work-material
fractures with the drill penetrating through the workpiece (Step
4). Finally, the hole is friction drilled with a petal-shaped bushing
formed (Step 5). Fig. 4 shows the overview and cross-sectional
images of a friction-drilled hole.
During the drilling process, the axial thrust force was amplified
by a multichannel charge amplifier (Kistler 5019A) and then
measured by a piezoelectric drilling dynamometer (Kistler
9257B). Surface temperature of drills during machining was
recorded by a thermometer (OS523-2, Omega Engineering Inc.),
which can measure temperatures ranging from 18 to 1370 1C
with accuracy of 71%. The temperature and axial thrust force data
were fed into the computer via the analog input module (NI, USB-
9215, National Instruments Corporation) and analyzed by Lab-
VIEW Run-Time 8.2.
Tool wear was observed after each drilling using an image
measurement system (PSC-3000Pro, Pentad Scientific Corpora-
tion). The area on the drill to be observed is indicated in Fig. 2. The
greatest tool wear obtained after 20 drillings under each
machining condition was analyzed. To understand the changes
in the distribution and loss of elements in both the workpiece and
cutting tool, the cross-section of drills was examined using
scanning electron microscope (SEM)/energy dispersive spectro-
meter (EDS) (5136LS, TESCAN, Czech Republic).
83
3. Results and discussion
3.1. Surface temperature of drills
Fig. 5(a)–(d) plots the highest temperature of the coated and
uncoated drill surfaces recorded at each drilling under spindle
speeds of 2400, 3600, 4800 and 6000 rpm, respectively. Compar-
ison of the figures reveals that the drill surface temperatures
recorded at 2400 rpm were the lowest among the four spindle
speeds. Moreover, the drill surface temperature increased with
increasing spindle speed because the higher the spindle speed, the
more the friction heat was generated. In addition, among the three
types of drills, UC drills had the lowest surface temperatures. As
for coated drills, the surface temperature of AC drills was higher
than that of TC drills. This phenomenon can be attributed to the
difference in thermal conductivity of the coating materials. As
mentioned above, the thermal conductivity of AlCrN is lower than
that of TiAlN [11], but the thermal conductivity of both AlCrN and
TiAlN are lower than that of tungsten carbide, which is around
80 W/m K. Heat produced during drilling can be dissipated easily
through the cutting tool, thus resulting in lower drill surface
temperature. However, drills with coating with low thermal
conductivity, such as AlCrN, tend to retain the heat energy
produced during drilling, and consequently have higher drilling
temperature.
Fig. 5 also shows a linear relationship between surface
temperature of drills and number of holes made. In other words,
the greater the number of holes drilled, the higher the surface
temperature of drills. This can be attributed to the greater surface
roughness of drills as a result of adhesion of tool to workpiece.
With increasing number of holes drilled, the friction coefficient
between the drill and workpiece also increases, thus raising the
surface temperature of drills during machining.
As mentioned above, coated drills had higher surface tem-
perature than uncoated ones. However, with increasing number of
holes, the difference in surface temperature between coated and
uncoated drills diminished. Such phenomenon is particularly
obvious at spindle speed of 6000 rpm. With repeated drilling,
wearing of AlCrN and TiAlN coatings occurred, turning coated
drills into uncoated ones with the drilling process performed by
tungsten carbide alone. Consequently, the difference in surface
temperature between coated and uncoated drills became smaller.
3.2. Tool wear
Fig. 6(a) displays the changes in maximum tool wear with
number of holes drilled at 6000 rpm by both coated and uncoated
drills. As can be seen, maximum tool wear increased with
repeated drillings made. UC drill suffered the maximum wear,
followed by TC one with AC drill having the least wear. The same
trend was also observed for drilling made at spindle speeds of
2400, 3600 and 4800 rpm (data not shown).
Fig. 6(b) compares the maximum wear suffered by the three
types of drills at the 20th drilling made at different spindle
speeds. As can be seen, UC drill had the most serious tool wear for
20 drillings made at 2400 rpm. The maximum tool wear suffered
by TC and AC drills were only 63% and 49% that suffered by UC
drill, respectively. However, the difference in maximum wear
among various types of drills reduced with increase in spindle
speed. In other words, the higher the spindle speed, the lesser the
protection of the coatings against tool wear will be.
According to Yao [14], the presence of coating on cutting tool
increases its hardness, which in turn enhances its wear resistance.
The research of Sharif and Rahim [8] and Jindal et al. [15] also
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Fig. 5. Maximum surface temperatures recorded for uncoated and coated drills at spindle speeds of (a) 2400 rpm, (b) 3600 rpm, (c) 4800 rpm and (d) 6000 rpm for 20 holes
drilled.

Fig. 6. Maximum wear of different types of drills (a) after 20 drillings at spindle speed of 6000 rpm and (b) at the 20th drilling at various spindle speeds.

indicated that AlCrN and TiAlN coatings could enhance wear
resistance of cutting tool by serving as solid lubricants.
It is worth noting in Fig. 6 that tool wear became more serious
with greater number of holes drilled and higher spindle speed.
However, the increase in tool wear was gradual rather than
abrupt, which is one of the characteristics of friction drilling.
Previous research on machining made by twist drills has pointed
out that increase in spindle speed raises the temperature of the
cutting tool, and the rise in machining temperature is the main
cause for tool wear. Jindal et al. [15] further added that the
increase in machining temperature at higher spindle speed
reduced the hardness of the cutting tool, which in turn under-
mined its wear resistance.
Fig. 7 plots the changes in maximum wear with surface
temperature of drills for 20 holes made at spindle speed of
6000 rpm by different drills. As can be seen, there exists a linear
relationship between the two. In other words, the higher the
surface temperature of drills, the greater the maximum wear
suffered. For coated drills, the increase in tool wear was not
significant for the first six drillings. With increase in number of
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S.M. Lee et al. / International Journal of Machine Tools & Manufacture 49 (2009) 81–88
Fig. 7. Relationship between tool wear and surface temperature of drills.
Fig. 8. Line-scan analysis of concentration of elements on cross-sections of (a) UC,
(b) TC and (c) AC drills.
holes drilled, tool wear then became more serious and obvious. At
the 20th drilling, although the surface temperature of both TC and
AC drills was higher, the maximum wear suffered by these coated
drills were relatively less than that by uncoated drill, with AC drill
having the least tool wear among the three. Furthermore, even for
drills with the same surface temperature achieved under
machining, the tool wear suffered were of different extent. The
same trend is also observed for machining made under spindle
speeds of 2400, 3600 and 4800 rpm (data not shown). Previous
studies have attributed the superior performance of AlCrN to its
85
better adhesive-fatigue resistance [10] and anti-oxidation capa-
city under elevated machining temperature [11], compared with
TiAlN coating.
Fig. 8 displays cross-sectional line-scan images of coated and
uncoated drills after 20 drillings made at spindle speed of
6000 rpm. As seen in Fig. 8(a), the surface of UC drill was found
to contain large amounts of Fe and Cr. This is attributed to the
adhesion and transfer of these two elements from the AISI 304
stainless steel workpiece. In friction drilling, most material
transfer is observed to be from the workpiece to the tool [1].
However, the distribution of these elements varied with the
position where the scanning was made. The concentration of Fe
and Cr diminished with increasing distance from drill surface or
when scanning was done closer to the tungsten carbide base
material.
Fig. 8(b) shows that both Ti and Al elements in the coating on
the TC drill surface became less, indicating a loss during friction
drilling. The same was true for both Al and Cr elements in the
coating on the AC drill, as seen in Fig. 8(c). Comparison between
the two shows that the AC drill retained a thicker coating than the
TC drill. It has been reported by Fox-Rabinovich et al. [10] that the
microhardness, reduced elastic modulus and impact fatigue of
AlCrN coating were enhanced when machining was performed
under elevated temperatures. However, TiAIN coating had de-
creased microhardness, reduced elastic modulus and less impact
fatigue with increasing machining temperature. Consequently,
AlCrN coating had better adhesive-fatigue wear resistance than
TiAIN coating.
It is also worth noting in Fig. 8(b) and (c) that both Fe and Cr
were present on the surface of the coated drills, indicating the
transfer of these elements from the AISI 304 stainless steel
workpiece to the cutting tool. Furthermore, comparing the
concentration of W and Co in the coated and uncoated tungsten
carbide drills shown in Fig. 8 revealed that the transfer of these
elements was the most obvious for UC drill even though high
machining temperature was produced by both TC and AC drills.
This offers evidence that the presence of coating can suppress the
transfer of W and Co, thus reducing tool wear.
3.3. Axial thrust force and torque
Fig. 9 displays the changes in measured axial thrust force and
torque of coated and uncoated drills, with the horizontal axis
representing the time and distance of tool travel from the initial
contact between tool and workpiece. As can be seen, the changes
in axial thrust force fell into four different regions described as
follows. Region A shows an abrupt increase in axial thrust force. It
is the time when the drill makes the initial contact with the
workpiece and drilling begins. Under constant high-speed drilling
between the cutting tool and workpiece, friction heat is generated
and the temperature rises above the recrystallization temperature
of the workpiece. High temperature softens and eventually melts
the workpiece, allowing easy penetration of the cutting tool, as
evidenced by the marked decrease in axial thrust force in Region
B. Further drilling in Region C pushes up the metal melted in
Region B and breaks into the workpiece, thus making a hole,
during which the increase in axial thrust force is gradual. Finally,
in Region D, with the hole made, drilling stops as evidenced by the
abrupt drop in axial thrust force.
Fig. 9(a)–(c) and (g)–(i) illustrates the changes in axial thrust
force with time from contact for the 1st and 20th drilling,
respectively, of different drills. Comparatively, the axial thrust
force at the 20th drilling was lower than that at the 1st. In other
words, axial thrust force decreased with increase in number of
holes made. Of note was the uneven growth in axial thrust force in
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Region C at the 20th drilling, which can be attributed to tool wear
of the drills. As can be seen, the fluctuations in thrust force were
more marked for the uncoated drill.
In contrast, the changes in torque could only be classified into
two different regions described as follows. In Region A, when the
drill comes into contact with the workpiece resulting in enhanced
friction between the two, thus causing the torque to increase. On
the other hand, in Region B, the conical part of the drill has fully
penetrated into the workpiece and reached the depth to be
machined. Further drilling has little impact on the interaction
between the cylindrical part of the drill and the workpiece, and
the torque thus decreases.
Fig. 9(d)–(f) and (k)–(l) illustrates the changes in torque with
time from contact for the 1st and 20th drilling, respectively, of
different drills. Comparatively, the torque at the 20th drilling was
lower than that at the 1st. In addition, as seen in all figures, the
higher the spindle speed, the greater the torque was, offering
evidence to the linear relationship between spindle speed and
torque.
Fig. 10(a) displays the changes in maximum axial thrust force
with number of holes drilled on the AISI 304 stainless steel
workpiece at 6000 rpm by both coated and uncoated drills. As can
be seen, maximum axial force decreased with repeated drillings.
Machining by UC drill produced more marked changes in
Fig. 9. Thrust force and torque at (a–f) 1st drilling and (g–l) 20th drilling of AISI 304 stainless steel workpiece at different spindle speeds.
maximum axial thrust force, followed by TC drill with AC drill
showing the least significant changes. The same trend was also
observed for drilling made at spindle speeds of 2400, 3600 and
4800 rpm as seen in Fig. 10(b). In addition, the difference in
maximum axial thrust force among various types of drills reduced
with increase in spindle speed. A rise in spindle speed will
increase the machining temperature, which in turn reduces the
axial force produced during drilling. Drill coating of low thermal
conductivity pose problems to heat dissipation. The friction heat
produced but not dissipated in turn leads to a reduction in axial
thrust force. With the thermal conductivity of AlCrN being lower
than that of TiAlN [11], the axial thrust force thus produced by AC
drill during machining under elevated temperatures was the
lowest among coated and uncoated drills.
Fig. 11 plots the relationship between maximum thrust force
and surface temperature of drills at spindle speed of 6000 rpm. As
can be seen, there exists an inverse relationship between the two;
that is, the higher the drill surface temperature, the lower the
maximum axial thrust force. For 20 holes made, UC drill showed
the largest change in drill surface temperature of 104 1C (range
718–822 1C) and the widest difference in axial thrust force of
412 N (range 1316–1728 N). On the contrary, AC drill had the
smallest change in drill surface temperature of only 63 1C (range
773–836 1C), and the narrowest difference in thrust force of 107 N
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S.M. Lee et al. / International Journal of Machine Tools & Manufacture 49 (2009) 81–88 87

Fig. 9. (Continued)

Fig. 10. Maximum axial thrust force of different types of drills (a) after 20 drillings at spindle speed of 6000 rpm and (b) at the 1st and 20th drilling at various spindle
speeds.

(range 1230–1337 N). A possible explanation of such is the machining temperature, the drills did not have the same axial
increase in microhardness of the cutting tool by the AlCrN thrust force. The presence of AlCrN and TiAlN coatings can serve
coating. Furthermore, Fig. 11 also reveals that even at the same as solid lubricants, thus reducing the axial thrust force produced.
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88 S.M. Lee et al. / International Journal of Machine Tools & Manufacture 49 (2009) 81–88
Fig. 11. Relationship between maximum axial thrust force and surface tempera-
ture of drills.
4. Conclusion
(1) During machining, surface temperature of drills increased
with increase in spindle speed. Owing to their difference in
thermal conductivity, the surface temperature of UC drill was
the lowest, followed by TC drill with that of AC being the
highest.
(2) Similarly, surface temperature of drills also increased with
repeated drillings or number of holes drilled. It is due to the
adhesion of tool to workpiece, AISI 304 stainless steel, which
enhanced the drill surface roughness and in turn raised the
friction coefficient of the subsequent drilling.
(3) At the same spindle speed and for the same number of holes
drilled, coated drills suffered less tool wear than uncoated
drill, with AC drill having the least tool wear. The difference in
tool wear became more significant and obvious with increase
in number of drillings made.
(4) At higher spindle speed, drill coating suffered greater tool
wear, and the difference in surface temperature between
coated and uncoated drills diminished.
(5) Line-scan images reveal that the presence of coating on drills
suppressed the transfer of W and Co from the tungsten
carbide base material to the drill surface and prevented
the transfer of Fe and Cr from the stainless steel workpiece
to the drill surface, both of which contributed to reduce
tool wear.
(6) After 20 drillings, UC drill showed more marked changes in
both axial thrust force and surface temperature than coated
drills. The presence of the TiAIN and AlCrN coatings resulted
in less significant variation in axial thrust force produced and
drill surface temperature. AC drill showed the least changes,
which helped contribute to longer tool wear.
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