Measurement 201 (2022) 111757

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Measurement
journal homepage: www.elsevier.com/locate/measurement

Advance monitoring of hole machining operations via intelligent

measurement systems: A critical review and future trends
Rüstem Binali a, Mustafa Kuntoğlu a, Danil Yu. Pimenov b, Üsame Ali Usca c,
Munish Kumar Gupta d, *, Mehmet Erdi Korkmaz e
a
Selcuk University, Technology Faculty, Mechanical Engineering Department, Konya 42130, Turkey
b
Department of Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, Chelyabinsk 454080, Russia
c
Department of Mechanical Engineering, Faculty of Engineering and Architecture, Bingöl University, Headquarters, Bingöl 12000, Turkey
d
Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St, 45-758 Opole, Poland
e
Department of Mechanical Engineering, Karabük University, Karabük, Turkey

A R T I C L E I N F O A B S T R A C T

Keywords: This review paper summarizes the application of smart manufacturing systems utilized in drilling and hole
Hole machining machining processes. In this perspective, prominent sensors such as vibration, cutting forces, temperature,
Industry 4.0 current/power and sound used in the contemporary indirect and direct tool condition monitoring systems are
Sensors
handled one-by-one according to their applications during machining of holes. Thus, it is aimed to show several
Smart manufacturing system
Tool condition monitoring
operations with the application stages and literature papers which utilize the sensorial data such as grinding,
reaming, broaching, boring, tapping, drilling and countersinking. The novel side of this paper is summarizing the
all-hole machining processes utilizing sensor systems while benefitting their predictive ability for improved
machinability characteristics such as surface integrity, tool wear, dimensional accuracy, chip morphology.

collected based on previously performed operations can be used as a

1. Introduction
Machining is a difficult operation because of extreme pressure and
temperature generated around the main cutting zone. Due to this case, it
is highly important to observe the cutting zone via advanced sensor
systems and to collect sensorial data with fastener equipment’s namely
hardware and software tools for signal processing [1]. The main element
of such system is sensors since they make the measurement of deter­
mined magnitudes such as heat, pressure and current [2]. Therefore,
selection of proper sensor is the primary issue in mechanical machining
processes. However, sensor systems with their additional devices are
highly costly and require capital cost in the perspective of industrial
companies [3]. When looking at the literature, there are many types of
sensors belong to various companies and equipped with numerous
specifications [4]. That’s why researchers, academicians and managers
of companies need prepared reports in today’s life to save time with
faster glimpse [5]. In this direction, there are two main approaches to
observe the cutting zone with advanced TCM systems. TCM systems
basically purpose to track the cutting tool and observe its behavior
developing a relation between sensor data. So, with the previous data
guide which can be done by the operators or integration of artificial
intelligence systems [6]. Therefore, it can be said that any sensor data
namely cutting force, vibration etc. can be used as information source to
understand the wear condition of cutting tool [7]. One of the TCMS
depends on the utilization such data which called as indirect method
owing to the requirement of external sensorial data. On the other hand,
direct monitoring systems need no sensor data which heavily based on
the detection of the wear condition directly on the cutting tool. This
paper addresses indirect TCMS applications focusing the applications of
sensor systems in hole machining processes. At this point it is important
to tell the place of the hole machining and its prominent application i.e.,
drilling.
Almost all engineering fields need to manufacture machine parts
with holes such as aerospace, aviation, medical, agriculture, bioengi­
neering, marine, transportation, vehicle, automotive, railway, military,
defense industry, mining etc. Holes are the vacancies produced as a raw
profile and/or machined as a further application in the main body [8].
There are qualifications defining the class of a hole determined by the
authors as represented in Fig. 1. Dimensional accuracy is the ultimate
aim of manufacturing industry since the whole chain of production is

* Corresponding author.
E-mail addresses: rustem.binali@selcuk.edu.tr (R. Binali), mkuntoglu@selcuk.edu.tr (M. Kuntoğlu), danil_u@rambler.ru (D. Yu. Pimenov), ausca@bingol.edu.tr
(Ü. Ali Usca), munishguptanit@gmail.com (M. Kumar Gupta), merdikorkmaz@karabuk.edu.tr (M. Erdi Korkmaz).

https://doi.org/10.1016/j.measurement.2022.111757
Received 27 May 2022; Received in revised form 22 July 2022; Accepted 12 August 2022
Available online 18 August 2022
0263-2241/© 2022 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
R. Binali et al. Measurement 201 (2022) 111757

Nomenclature MRR Material Removal Rate

PCBN Polycrystalline Cubic Boron Nitride
EDM Electrical Discharge Machining EWR Electrode Wear Rate
CFRP Carbon Fiber Reinforced Polymers AA Aluminum Alloy
CNC Computer Numeric Control LBM Laser Beam Machining
SEM Scanning Electron Microscope FRP Fiber Reinforced Polymer
EDX Energy Dispersive X-Ray Analysis FEM Finite Element Method
CGI Compacted Graphite Iron UPD Ultrasonic Peening Drilling
FESEM Field Emission Scanning Electron Microscopy MQL Minimum Quantity Lubrication
HSS High Speed Steel ECDD Electrochemical Discharge Drilling
AWJ Abrasive Water Jet CCD Charge Coupled Device
CARALL Carbon Fiber Aluminum Laminates TCM Tool Conditioning Monitoring
CMM Coordinate Measuring Machine LFVAD Low Frequency Vibration Assisted Drilling
mEDM Micro Electro Discharge Machine PCB Printed Circuit Board
AISI American Iron and Steel Institute HFIM High Frequency Impulse Measurement
GFRP Glass Fiber Reinforced Polymer TCM Tool Condition Monitoring
PVD Physical Vapor Deposition TCMS Tool Condition Monitoring Systems

developed the wellness of this final product [9]. Hole size and circularity
are the main characteristics that determines the accuracy. On the other
hand, burr formation is encountered as a defect during cutting of the
holes which need to be eliminated [10]. Roughness has a global allow­
ance to define the quality of a surface which can be measured by many
parameters guaranteed by the standards [11]. In sum, hole production
with high quality is an important case that is characterized by several
factors. However, it should be noted in here that all of these quality
indicators are heavily affected by the tool wear development. This case
is valid for all machining types but in the example of hole machining this
may be more complex mostly due to the machining zone is too small and
chip evacuation process is difficult. As a result of this, higher chatter
vibrations, cutting forces and temperatures may be observed. After that,
excessive tool wear, poor roughness, burr formation and poor dimen­
sionality is highly possible to observe. Thus, integration of sensor sys­
tems has a major significance on the monitoring of machining responses.
In the perspective of the collected information, presented paper pur­
poses to discuss the current literature of hole machining which utilizes

Fig. 1. Main characteristics of hole quality [12].

2
R. Binali et al.
sensor systems. With this approach, hole machining processes including
drilling are summarized. By this way, the prominent sensor types,
machined materials, the most addressed quality indicators of holes can
be easily seen. In this direction, tool wear, dimensional accuracy and
surface roughness parameters will be analyzed in depth.
Hopefully, the presented approach will be useful as a guideline for
both people in academic community and industry who looks for specific
application of sensors in hole machining. Main aim of the presented
paper is being a handbook for the future studies as determining the
mostly preferred sensors of indirect TCMS and their positive and nega­
tive sides and their predictive roles on determining the hole quality
characteristics such as dimensional accuracy, tool wear and surface
roughness. The readers of this review paper can find the simple briefs of
hole machining operations and regarding sensor system integrations
along with their efficiency on monitoring the hole machining charac­
teristics. In the course of the paper, hole machining processes such as
grinding, reaming, boring, drilling, broaching, countersinking, honing
will be defined in the section 2 with classifying them indirect and direct
TCMS. Main machining characteristics for hole machining operations
namely tool wear, surface roughness and dimensional accuracy will be
described and detailed in the light of the literature papers in the section
3. Different sensors used namely cutting forces, vibrations, current/
power, temperature, acoustic emission and multiple sensors in the
machining area will be handled after that one-by-one in the section 4.
2. Classification of different sensor systems for tool condition
monitoring in hole machining
2.1. The hole machining processes
Different from the outside cutting as can be seen in face turning or
milling operations, metal cutting in the hole is a difficult task mostly due
to the narrow area do not allow elimination of the chips easily and
carries a lot of risks [13]. Since metallic chips have the most part of the
heat at the cutting zone, it is imperative to remove the chips quickly
[14]. This is a critical issue to obtain longer cutter life and preserve the
quality of the surface in a desired range [15]. Because, existing tem­
perature of cutting tool accelerates the wear mechanisms namely
diffusion and adhesion and finish the remaining useful lifetime. On the
other hand, mechanical properties of the machined work material will
be affected from excessive heat. That’s why determination of the process
quality has a great importance in hole machining operations. Sensors are
the primary objects to monitor the developments in the cutting zone and
preferred numerous times by the researchers. The hole machining pro­
cesses can be sorted as grinding, reaming, broaching, boring, drilling
and countersinking as represented in Fig. 1.
Hole grinding: In the internal grinding process, chips are removed
from the inner parts of the part. According to the technical drawing of
the part to be grinded, different stones are used in the internal grinding
machine. Some of these may be cylindrical, while others may be conical
or similar specially manufactured stones. In the process, after the part to
be grinded is fixed to the machine mirror and the secretions are
removed, the length adjustment is made. The stone connected to the
reciprocating spindle is adjusted according to the inside of the hole. The
chip removal process is performed by bringing the stone inside the piece
closer to the inner surface.
Reaming: Reaming is a process conducted to achieve the aspired
dimensions with a higher quality. The hole drilled with a cutter may not
be in the exact size, and the surface cannot be achieved in the range of
the required quality. When it is aimed to produce a smooth surface, the
main thing should be drilling the hole into the little smaller than its size.
Then reaming operation needs to be applied to bring it to full size.
Boring: Boring is a machining process used to enlarge or improve the
quality of an existing hole. There are many flexible tool systems avail­
able when boring, covering a wide range of diameters, from roughing to
fine boring.
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Measurement 201 (2022) 111757
Drilling: Drilling is generally carried out when finishing of the
production procedure after a number of operations to increase the di­
mensions of the initial part. Despite drilling operation is accepted as a
simple way to operate, it is a complex process that may cause important
problems when the cutting tool breaks or failures if it is used beyond
capacity.
Broaching: Broaching is a machining process with a cutting tool
called a broach with geometrically defined cutting edges. In broaching;
broaching tools generally have a profiled die, which are the inner or
outer surfaces of the workpieces. Broaching is used in mass production
where high surface qualities and profiles with large shape accuracy must
be produced. Because the broaching tools are very expensive but
economical for production of large quantities of parts.
Countersinking: Countersinking is a process that may be used for
drilling conical or cylindrical slots into pre-drilled holes. Such procedure
may be operated with improved drills. Countersinking has many pur­
poses. Mostly, these operations are utilized to open the slots where the
head of fasteners such as rivets and screws will fit.
Honing: Honing is the finishing step to achieve precise hole geom­
etry and surface finish by removing rust with cutting wheels. Honing is
the most effective method used to get the correct dimensions of cylin­
drical holes. Thanks to this application, the engine cylinders are brought
to the most correct form. Honing process; It is made by means of honing
stones consisting of abrasive materials such as aluminum oxide, silicon
carbide, diamond. Drilling and in-hole processes (Grinding, reaming,
boring, drilling, broaching, countersinking and honing processes) are
schematically given in Fig. 2.
2.2. Indirect and direct sensor systems for tool condition monitoring in
hole machining
The chip removal event is an extremely complex event influenced by
many variables. Therefore, it is not possible to detect tool status with a
single sensor. TCMSs provide a holistic approach in order to monitor the
cutting zone with higher precision with the help of sensor systems. In
addition to advanced sensors, such systems utilize the contemporary
software systems and signal processing approaches for detailed analysis
of the collected data. TCMS, an advanced warning system on tool and
chip removal, reliable information on the state of the chip removal
process, information on tool wear to ensure workpiece tolerance, and an
early warning system for tool breakage are installed to analyze and
provide information. There are two basic methods that evaluate the tool
condition based on the detection of the wear level: i) indirect method, ii)
direct method. Indirect methods are proper for the industrial applica­
tions since they do not interfere the machining system. It is highly
important not to stop the cutting operation to obtain sustainability and
better surface forms through the workpiece material. In addition, data
about the state of the cutting tool are obtained by measuring operations
during chip removal. Indirect measurement methods are as follows:
Measurement of cutting forces, acoustic emission, noise, vibration,
motor power and current, measurement of heat at the cutting point,
measurement of surface roughness and multiple measurement methods.
Direct methods use different methods during the cutting process to
measure when the production stops and determine whether the tool life
is over or not. Two important criteria in this method are the selection of
sufficient input sensors and the establishment of an effective fusion
model. The sensor outputs are expected to show linearity with the
sensed properties. Theoretical models are limited in their use because
they rely on very few measurable variables and sensor data. For this
reason, experimental data are mostly used in established models. Direct
measurement methods are optical measurement, measuring with con­
tact probes, electrical resistance method, radioactive rays’ method,
observing the change in workpiece dimensions, observing the cutting
tool-workpiece distance. In direct methods tool life and wear amount are
determined by measuring the volumetric reduction in the cutting tool
when the cutting tool is not used. In indirect measurement methods, the
R. Binali et al.
Fig. 2. Hole machining operations generally operated in the literature.
parameters of the cutting functions are measured. One of most widely
used of these methods is the measurement of cutting forces. Measuring is
done during chip removal and measured force variations give informa­
tion about the state of the cutting tool. The direct measurement tech­
nique has specific drawbacks which can be sorted as the cutting process
must be stopped before the measurement is made, the wear on the
cutting tool during normal cutting differs due to the abrasions that occur
during the first cutting, and the volumetric measurements made give
erroneous results. In addition, there are disadvantages such as not being
suitable for the industrial environment and production chain according
to the business functions. Comparing these two approaches, it is possible
to say that they are both highly costly since they require investment cost
and additional equipment’s depending on the surroundings such as
computer, signal processing and analysis devices, mechanical attach­
ments etc. However, when looking at the applicability in the industry, it
is possible to say that indirect methods can compensate the initial costs
with their efficiency and contributions on the improvement of cutting
tool life. In addition to that improvement of tool life and preventing
harsh wear mechanisms provide to obtain better surface integrity and
dimensional complement. In this direction, previous researchers pro­
posed a number of sensors to monitor the cutting environment. There­
fore, this study aims to observe the cutting zone of hole machining
4
Measurement 201 (2022) 111757
operations with the help of several sensors. The handled sensor types are
given in Fig. 3 in the perspective of this study.
3. Quality characteristics of holes in machining
When looking at the quality standards of holes after applying a
machining operation, there are several parameters that need to be
considered in order to evaluate the process as successful. In this direc­
tion, the authors observed that previous studies mainly focused on three
response indicators in sensor integrated TCM based hole machining
operations. They will be explained initially as handling the literature
review.
3.1. Tool wear
Wear is the loss of material that usually occurs on the cutting tools
which utilized in the machine tools. In machining operations, deter­
mined wear level represents the end of the effective cutting time, in
which case the cutting tool material loses its original profile or causes
material loss owing to the interaction of the workpiece and cutting tool.
Consequently, it is not possible to obtain a product with the desired size
and measurement precision on the material while using a worn tool. As a
R. Binali et al.
Fig. 3. Graphical abstract of the sensor systems used in indirect TCMS.
result of excessive wear, it is not possible to obtain the desired size and
dimensional accuracy [16]. All of the cutting tools wear down during the
chip removal processes and continue until the life of the cutting tool is
completed [17]. As in other machining methods, it is very significant to
designate the optimum values of the cutting parameters in hole drilling
process. Machining parameters directly affect the angles of the cutting
tool, instead indirectly [18]. For example, increasing feed rate decreases
the clearance angle while increases the helix angle. A decrease in the
clearance angle will increase the friction of the main flank of the cutting
tool with the processed surface, resulting in an acceleration of flank
wear [19]. The abrasions on the cutting tools, which are generally used
for drilling and in-hole operations, start from the junction point with the
armor shield of the cutting edges and continue on the edges of the cut­
ting tool and free surfaces [20]. Considering wear at drilling and
machining tools, such deformations cause poor chip formation, cutting
edge wear, chipping at the corner of the tool, chipping of the cutting
edge, wear in the circular area of the cutting edge and plastic defor­
mation [21]. Tool wear in drilling tools is given in Table 1.
Tool wear is of the main outcomes in machining operations that need
to be measured after determined time. The researchers put forward this
case and the authors of this paper preferred to outline tool wear mea­
surements in the course of this study. Some examples of this topic are
given in the following. Fernández-Pérez et al. [23] investigated on
minimizing the position errors and tool wear after the drilling of com­
posite fiber reinforced polymer material. Mikloš et al. [24] studied on
the assignation of tool wear in the course of the drilling process of C56E2
bearing steels. The axial wear of the tool electrode is approximately
proportional to the number of holes machined. They also determined
that the axial wear of the electrode increased with increasing depth-
diameter ratios. Najiah Dahnel et al. [25] conducted the effects of dry
and cutting fluid use on tool wear in drilling Al7075 alloy material. As a
5
Measurement 201 (2022) 111757
result of their studies, they stated that the use of cutting liquid causes
lower tool wear to dry cutting. The use of coolant resulted in 42%, 38%
and 30% lower tool wear at 22, 44 and 66 m/min, respectively,
compared to dry drilling. For this reason, they stated that it is necessary
to use coolant and lower cutting speed to reduce flank wear and thus
extend tool life. Liu and Bai [26] investigated the axial wear of the tool
electrode and the simulation analysis of the flow rate of the working
fluid, which plays a significant role in cleaning the discharge debris, for
the purpose of ensure the accuracy of the process in the micro-hole
array. Attanasio et al. [27], studied numeral simulation of tool wear
during drilling of Inconel718 material. They determined that the pro­
cedure developed for capturing tool wear in drilling was correct. Dog­
rusadik and Kentli [28] investigated the wear of micro drill by
considering the effects of backing plates in drilling fiber reinforced
composites. Bai et al. [29], studied on a semi-analytical model to predict
the progression of tool wear, combining main interaction analyzes
among workpiece and cutting tool and regression analysis in drilling
composite fiber reinforced plastic with a carbide drill. As a result, they
found that the prediction error of the tool wear rate model was within
24.02% with only one test group for the wear coefficient calibration. In
addition, with their analysis, they stated that changing the two wear
coefficients by ±5% and ±10% would cause estimation variations of the
tool wear rate in the range of 2.78% and 5.56%, respectively. Sharma
et al. [30], investigated tool wear and chip formation in the course of the
drilling of flat glass (Fig. 4). In Fig. 4, the material they used in their
work, the set-up of the experimental setup on the machine tool, the post-
processing view of the cutting tool and workpiece are given.
In their study, Yarar and Karabay [31] conducted the effects of
cutting parameters on tool wear in ultrasonic assisted drilling. As a result
of the study, they determined that ultrasonic vibration has the effect of
reducing the buildup edge formation on the drill bit. Gaugel et al. [32],
R. Binali et al. Measurement 201 (2022) 111757

Table 1 Inconel718 superalloy to investigate the cryogenic machining potential.

Tool wear in drilling tool. As a result of their experimental studies, they found that tool wear was
Wear Type Of Possible Causes Solutions significantly reduced depending on the temperature when compared to
Drilling Tools [22] dry drilling and cryogenic drilling, which resulted in a reduction of
Build up edge Very low cutting speed Increase the cutting speed or approximately 30% in torque values. They also stated that the cryogenic
and edge temperature use external cutting fluid drilling process increased the tool life by approximately 87.50%. Alonso
No coating Sharper cutting edge should et al. [42] conducted the effect of slot number and stepped bit geometry
Very low oil percentage in be used on tool wear and force when drilling CFRP/Ti6Al4V stacks. Xu et al.
cutting fluid Edge coating should be done
The oil percentage in the
[43], conducted the drillability and tool wear of CFRP material in a
cutting fluid should be study involving candlestick drills and step drills (Fig. 5). Fig. 5 shows the
increased. setup of the experimental work, the cutting tool, the workpiece material,
Chipping on Unstable fixture Fixture should be checked the dynamometer, the drilling zones and the matrix of the composite and
periphery Intermittent cutting Radial deflection should be
the steps of the process. Finally, Table 2 overviews tool wear studies
Insufficient cutting fluid checked
Unstable tool holder Feed rate must be reduced about hole machining summarizing different operations, workpiece
Cutting fluid supply should be materials and main aim of the paper.
checked. Conclusion on the subsection: Despite tool wear is a natural pro­
Tool holder should be cess in machining environment, it is undesired when the control on it is
checked
Flank wear on main Cutting speed too high Cutting speed should be
lost. Mostly, monitoring of the tool condition is possible during tests on
edge Feed rate too low reduced lathe or milling machine. However, drilling and hole machining oper­
Quality is very soft Feed rate must be increased ations are difficult to observe the changes on the tool which makes it
Insufficient cutting fluid A harder grade should be used critical to protect anomalies such as chip tangling, tool breakage, chip
It should be checked that the
squeezing, excessive adhesion wear, fatigue wear etc. Such changes
cutting fluid supply is correct.
Chipping on main Unstable conditions The mechanism should be affect hole dimensions producing burr in the hole and results in poor
edge Maximum permissible checked surface integrity. Therefore, integrated sensors around the holes are
wear exceeded Drill should be replaced soon useful technical equipment’s for improved machining quality. When
Quality is too harsh A softer grade should be used looking at the literature review, drilling is the governing operation over
Flank wear on Cutting fluid too weak Radial deflection should be
other types considering the researcher preferences. As can be seen that
circular land Cutting speed too high checked
Abrasive material Pure oil or stronger emulsion modeling, optimization, simulation, micro and macro-observations on
should be used. tool wear diagnosis are preferred in the main purpose of the studies on
Cutting speed should be hole machining processes. It should be noted that there are a few
reduced
numbers of papers contains the sensor-based tool wear monitoring in
A harder grade should be used
Plastic Deformation Cutting speed and/or feed Cutting speed and/or feed hole machining which can be a new perspective of future works.
too high should be reduced
Insufficient coolant The pressure of the cutting 3.2. Dimensional accuracy
supply fluid should be increased
Inappropriate quality A harder grade should be used
Drilling is done in a closed and narrow area within the part. In this
case, the evacuation of the chips from the cutting tool via helix channels
conducted comparisons of tool wear and in-process delamination when causes the chips to compressing, causing the tools to break and the
drilling carbon fiber reinforced polymers. In their study, they reported drilling process to be a complex and difficult situation due to the high
that measuring cutting edge rounding is a suitable method for charac­ temperatures that occur during cutting [44]. Due to technological ad­
terizing tool wear of uncoated carbide drills in machining CFRP, but vances, it is desired that the inside of the hole should be with high
cannot be reasonably applied to coated drills due to minimal changes in precision. The precision level is defined with some parameters such as
cutting edge rounding during coating wear. Xiang et al. [33] studied the hole diameter, dimensional accuracy, surface roughness and cylin­
tool wear in the course of drilling of SiCp/Al matrix composite materials dricality in drilling operations [45]. After the drilling process, the holes
containing copper. De Oliveira et al. [34] conducted the drilling of are also reamed in addition to the drilling process in order to provide
compacted graphite iron material the cutting edge wear of carbide tools high quality. However, with the combination of modern machine tools,
coated with TiAlN. Klaic et al. [35] studied tool wear in drilling practices help of technology with modern cutting tools, high quality drilling is
using vibration signals. The drill wear properties were obtained using possible. In order to achieve this, the processing parameters must be
the frequency domain of vibration signals measured in all three chosen at an optimum level. Primary problems encountered during
orthogonal directions. Malayath et al. [36] focused a new tool wear machining operations reveals due to the chatter vibrations [46], lubri­
recompense procedure integrating an image operation module and a cating and cooling medium and excessive wear of the tool. The dimen­
computer controlled tool wear estimation algorithm for drilling tungsten sional accuracy of the hole depends on the desired diameter and
carbide material on an EDM machine. They stated that the method they tolerance values according to the values given in the design. Diameter
used created a deviation of 0.3–1% from the intended depth of the hole. values with desired dimensional accuracy also allows the materials to be
Roopa et al. [37] investigated both temperature and tool wear focusing joined during assembly [47]. In this perspective, a variety of papers have
on the drilling of hardened EN8 alloy steel. They stated that the tool been published according to the open literature. D’Orazio et al. [48]
wear increased with the increase in cutting speed. In another study, Kuo investigated the drilling operation of CFRP/AA7075 stacked material by
et al. [38] conducted the wear behavior of coated tools during drilling of virtue of tool wear, cutting force and hole quality with dimensional
CFRP composite materials. Koopaie et al. [39] performed tool wear and accuracy. Zhu et al. [49] studied electrochemical removal and grinding
temperature in drilling bone with zirconia and tungsten tools. Li et al. for machining sensibility small holes in difficult-to-machine stainless
[40] made tool wear operations in drilling of Ti6Al4V/CFRP stacked steels. They examined the suitability of hybrid machining based on
material. They reported, compared to conventional drilling processes, dimensional accuracy and hole surface quality. The grinding and elec­
forced air-cooled low-frequency vibration-assisted drilling prolongs tool trochemical removal and process steps, which are the methodology of
life by reducing sticking and side wear in drills. Khanna et al. [41] this study, are shown in Fig. 6.
examined the workpiece hole quality and tool wear in drilling In another study, Zhu et al. [50] studied ultrasonic assisted electro­
chemical drill grinding for high quality and accuracy machining of small

6
R. Binali et al.
Fig. 4. Experimental setup in the paper of [30].
holes. Klein et al. [51] worked on predicting the surface and dimensional
quality characteristics of honed holes using machine learning method.
Zhang et al. [52] investigated the hole properties and surface damage
formation mechanisms of abrasive water jet-treated Cf/SiC composite
materials. Rathinasuryan et al. [53] investigated the optimization of the
roundness of the Ti–6Al–4V alloy of machining parameters (current,
speed and stand-off distance) in plasma arc drilling using the Taguchi
method. Liu et al. [54] focused on physical experiment and statistical
applicability of micro hole machining for drilling of Cf/SiC composite
material. Bolar et al. [55] researched the helical milling and drilling
process for drilling holes in Cf/Al laminates. As a result of their studies,
they evaluated the force, roughness, chip morphology, temperature,
hole size and burr size. Prasad and Chaitanya [56] conducted the effect
of cutting parameters on dimensional accuracy and surface roughness
when drilling GFRP composite materials using abrasive water jet
method. As a result of the study, they stated that the standoff distance
and fiber orientation angle are the main factors affecting the surface
roughness value and dimensional accuracy. Vignesh et al. [57]
compared the metal removal rate, roughness and dimensional accuracy
of the drilled surface with uncoated and coated HSS drill tools on SS410
stainless steel material. Comparison of the performance of coated and
uncoated drill bits showed that coated drill bits have higher perfor­
mance than uncoated. By using coated drills surface Roughness and
Ovality values of drilling are reduced to an extend of 48.5% and 2%.
Material removal rate value is also improved to an extend of 23%. Singh
et al. [58] investigated the optimization of machining parameters for a
composites performance characteristic based on hole diameter accuracy
and surface roughness when drilling EN-31 alloy steel material. They
used gray relations analysis in their studies, and as a result the estimated
value was 0.832, which was improved by 2.9%. Unune et al. [59]
studied the accuracy and quality of micro-holes created as a result of
vibration assisted micro electro discharge drilling of Inconel 718 alloy
material. Quadratic models for metal removal ratio, electrode wear
ratio, overcut, and taper angle indicated that their experimental results
7
Measurement 201 (2022) 111757
reliably occurred with prediction errors of less than ±7%. Zhong et al.
[60] investigated the quality and/or accuracy of punching CFRP/Al/
CFRP stacked materials. They stated that TiAlN coated drills promote
59.1–92.5% lower delamination factors than uncoated drills because
TiAlN coating helps to reduce thrust forces in drilling. Jia et al. [50]
investigated the multi-edge drill structure to improve hole quality and
dimensional consistency when drilling Ti/CFRP stack materials. As a
result of the experiments, it was determined that the polyhedral struc­
ture was effective in reducing drill-out delamination, CFRP burrs and Ti
burrs in Ti/CFRP drilling, while the hole diameters were controlled by
the drill bit within the desired tolerance. Zou et al. [61] investigated the
feasibility of drilling CFRP/Al occurred material with the mechanism of
low frequency vibration assisted drilling. They noted that low-frequency
vibration-assisted drilling narrows the gap between the drilled hole size
of the hardened material and the theoretical nominal diameter, and with
the increase of vibration amplitude, the geometric accuracy is signifi­
cantly improved, given the reduced hole cylindricality. In this study, the
sensors and experimental setup used for the measured shear force,
temperature and vibration values, except for the dimensional accuracy,
are given Fig. 7.
Muthuramalingam et al. [62] conducted the effects of cutting pa­
rameters in the laser beam machining when drilling holes on the
Taguchi experimental approach on Ti-6Al-4V alloy. They stated that the
power parameter has the most important effect for evaluating dimen­
sional accuracy quality measures such as roundness and ovality in the
laser beam machining process. Lv et al. [63] studied the effect of high
frequency vibration on hole integrity in rotary ultrasonic drilling of
carbon fiber reinforced polymer composite materials. Cao et al. [64]
studied a delamination estimation model using ultrasonic vibration
assisted drilling with a core drill or abrasive diamond hole saw to
calculate the delamination factor and thickness that occurs after drilling
carbon fiber reinforced polymer materials. Singh et al. [65], used kevlar-
29 fiber composite material in their work. Parametric optimization and
experimental investigation of hole circularity and taper angle during
R. Binali et al.
Fig. 5. Experimental setup and schematic view [43].
laser drilling of the material they used were carried out. As a result of
their work, based on the parametric analysis, lamp current has been
found the most important factor for the hole circularity while air pres­
sure as less important parameter in laser drilling of CFRP composite.
Balaji et al. [66] investigated parametric optimization in drilling of 304
stainless steel with abrasive water jet. Dewangan et al. [67] researched
the optimization analysis of machining parameters in the micro electro
discharge machining process of Ti6Al4V material with dimensional ac­
curacy. Table 3 overviews the literature papers published in this topic
including different workpiece materials, processes, the main aim of
these papers.
Conclusion on the subsection: Dimensions of the machine part
became one of the critical goals in machining route as the precision
engineering gained importance with the industry 4.0 aim in all over the
world. Accurate parts show the quality of the engineering, company and
industrial development in applying of advanced methods. Also, it is
significant to address those holes are one of the most important parts of
parts as they provide connection between two different elements during
assembly period. Wear behavior, corrosion and oxidation resistance,
preserving the texture quality are heavily depends on the quality of
holes. In this direction, quality assessment of the holes refers to the
attention and development level in terms of technology of a company.
Seemingly, optical microscope, CMM and SEM are the preferred ways
for determination of the dimensional accuracy of the holes in the liter­
ature. Some studies used sensorial devices to detect the verification of
the dimensional abnormalities according to the previous papers. High
quality part production with evaluating roughness and accuracy are the
general aim of the handled studies. This was done by modeling, opti­
mization and testing approaches when the literature papers are
8
Measurement 201 (2022) 111757
analyzed.
3.3. Surface roughness/integrity
It is necessary to consider the input parameters belong to machine
tool and responses such as surface quality, tool wear and cutting forces
related variables in the course of the chip removed in machining pro­
cesses. Some of them can be listed as the cutting tool material and ge­
ometry, the rigidity of the machine and workpiece material. The
roughness and precision of the machined material surface are important
output parameters as they determine the final purpose of the machined
part [68]. The sensitivity of the surface is the term that includes many
parameters, and these are the factors such as the surface finish, cracks on
the surface, chemical change, burning marks and permanent tensile
stress on the workpiece. For this reason, precision on machined surface
is one of the most significant output parameters in machining. Mini­
mizing the surface roughness value and obtaining the desired quality are
the main goals in the finishing processes. For this reason, the machining
conditions and process parameters can be determined by considering the
desired surface roughness quality. In addition to these situations, each
parameter used during machining affects the surface integrity. Surface
roughness is not only dependent on traditional aspects of tribology such
as friction, wear and lubrication, but also an important factor to be
considered in divergent fields like sealing, electricity, hydrodynamics,
heat conduction. Thereby, it is very significant to obtain the surface
roughness values of the machine workpieces [69]. The factors affecting
to surface roughness in machining operations can be summarized with
two independent variables. They can be sorted as i) ideal surface
roughness and ii) natural surface roughness [70]. Roughness index is
R. Binali et al. Measurement 201 (2022) 111757

Table 2
Literature review of tool wear studies about hole machining.
Type of sensors Machining Process Workpiece Aim Ref.
operations

Optical microscope, Drill Machine Countersinking CFRP To examine the wear operation of countersunk drill bits used in the [23]
profilometer aviation industrial and to appraise its effect on hole quality.
Digital microscope Drill Machine Drilling Bearings steels Monitoring of indexable bit drill wear intensity. [24]
Microvue 8.0MP C56E2
Microscope with VIS Pro CNC Milling Machine Drilling Al7075 Investigations of the effects of drilling circumstances and [25]
software machinability parameters on burr formation and tool wear in the
course of drilling of Al 7075 material.
Observation and EDM Micro Drilling Stainless Steel It is the study of the effect of working liquid on the axial wear of the [26]
calculation tool electrode.
Deform-3D software Three-axes CNC Drilling Inconel 718 It is to simulate tool wear. [27]
milling
machine
SEM CNC machining center Micro drilling CFRP laminate It was purposed to measure flank wear more exactly. [28]
Alicona Infinite Focus G5 Milling machine Drilling CFRP It is to construct a semi-analytical tool wear progression model. [29]
Optical microscope Rotary ultrasonic Drilling Float glass Reducing chip formation by optimizing machining factors. [30]
machining
SEM and EDX images Drill machine Drilling AA6061 To examine the effects of cutting parameters on tool wear, [31]
roughness and cutting force.
Optical fringe projection 4 axis CNC machine Drilling CFRP Determining and measuring the damage that occurs in CFRP [32]
material in the curse of the drilling operation with effective optical
methods
3D laser scanning CNC machining center Drilling Al6063/SiCp/65p To studied the micro-mechanism underlying macro scale wear of [33]
microscope tools when drilling SiCp/Al composites.
Keyence CNC machining center Step drills and CFRP laminate Determining the wear characteristics of a step drill and a [43]
VHX-500FE microscope candlestick drills candlestick drill when machining CFRPs.
Optical microscope Turning Drilling CGI (compacted To define the cutting tool flank wear during the drilling of the CGI [34]
graphite iron) and to correlate it with the quality of the holes formed.
Industrial camera Custom-made triaxial Drilling Rock To Determine whether vibration signals generated during rock [35]
milling drilling can usefully classify tool wear levels.
machine
A microscope with camera EDM Blind hole drilling Tungsten carbide Determination of tool wear by image processing techniques [36]
Tool microscope and laser – Drilling EN8 Determination of tool wear and changes in interface temperature [37]
sensor during drilling
SEM CNC machining center Drilling CFRP To explain the relationship between tool wear and breakage in [38]
diamond-coated tools.
SEM Vertical Machining Drilling Bone Evaluation of temperature and wear variations of two conical tools [39]
Center made of tungsten carbide and zirconium dioxide.
Digital microscope and SEM CNC machining center Drilling CFRP/ Investigating tool wear problems [40]
Ti6Al4V stacks
FESEM and tool maker’s Three-axis CNC Drilling Inconel Exploring the potential of cryogenic processing. [41]
microscope vertical machining 718
center
Dynamometer, confocal Five-axis CNC Drilling CFRP/ Reveal the impact of step drill design on cutting forces and tool [42]
microscope, SEM, machining Ti6Al4V stack wear
internal center
micrometer and optical
microscope

determined by comparing the surface to be investigated with a known
surface, measuring with tracer probes or optical devices. Methods
include contact, mechanical, hydraulic, surface dynamometer, X-ray,
electron microscope, replica and Electro fiber optic, tracer tips, and
optical profilometer methods [71–75]. Surface integrity, on the other
hand, refers to various machined surface conditions as well as surface
quality [74,76,77].
Liu et al. [78] performed experimental work to develop the surface
roughness of micro-holes in high Ni alloy materials. Ma et al. [50]
investigated the surface quality of 304 stainless steel material as a result
of ultrasonically assisted honing. Gu et al. [79] investigated the
improvement of mechanical and metallurgical surface integrity of
machined Ti6Al4V alloy hole surface using multi-step milling and
sequential laser shock forging. Subhedar et al. [80] measured the effects
of Al2O3 Nanoparticles/Mineral oil-based coolant on surface roughness
and tool life in the course of drilling of Stainless Steel 304 material.
Rajaguru and Arunachalam [81] investigated the effects of ultrasonic
vibrations in deep hole drilling of A36 steel material. They applied their
work by giving ultrasonic vibration to the workpiece. They evaluated
the drilling process with chip morphology, cutting force, tool wear, post-
process hole quality, roughness and processing time. Khunt et al. [82]
done drilling experiments with a minimal amount of vegetable-based
lubrication system. In their experimental studies, they evaluated the
drillability of AA 6063 material on the basis of thrust force, axial force
and surface roughness. Graves et al. [83] performed a study based on the
comparison of surface roughness for holes created in Ti5553 material
with both uncoated WC/Co and TiAlN PVD coated tools at low and high
cutting speeds and feed rates. Zhang et al. [84] investigated the element
composition, surface morphology, residual stress, microhardness and
reform layer properties of holes treated with electrochemical discharge.
They stated that by increasing the conductivity of the working fluid, the
surface roughness decreased. Karabulut and Kaynak [85] performed the
drilling tests of Inconel718 alloy produced by selective laser melting
additive manufacturing. As a result of their experimental studies, surface
quality, surface topography, subsurface microhardness and surface and
microstructure were examined. As a result of their studies, they reported
that the selective laser melting additive manufacturing method helps to
develop the processed surface quality of the materials. Chen et al. [86]
investigated the hole output quality and machined surface integrity of
drilled Cf/SiC composites. They stated that the surface roughness
decreased with increasing cutting speed and increased with increasing
feed rate. Azim et al. [87] studied the surface integrity and cutting forces

9
R. Binali et al.
Fig. 6. Schematic view grinding and electrochemical removal [49].
in micro-drilling of Nickel based superalloy material. Inada et al. [88]
carried out the design and manufacture of a small diameter deep hole
drilling machine. They determined the suitability of the machine with
experiments. In their experimental studies, they evaluated the concen­
tricity, roundness, hole diameter and inner surface roughness of the hole
by drilling the Ti6Al4V material. They emphasized that a constant hole
diameter of 0.99 mm at the entrance, middle and exit of the φ1.0 × 400
mm drilled hole for Ti6Al4V is a highly desirable result. Kumar Verma
et al. [89] carried out experimental investigations on circularity error
and surface roughness when drilling of Polymer nanocomposite mate­
rials. Zhang et al. [90] investigated the surface integrity for wet and dry
drilling of 49Fe49Co2V alloy material. The surface roughness and fine
grain zone thickness of dry drilled holes are greater than wet drilled
holes; They stated that the work hardening caused by wet drilling is
higher than that of dry drilling and chips are formed at the exits of wet
drilled holes due to material brittleness that can be prevented by dry
drilling. Khadtare et al. [91] made surface integrity investigations for
straight and curved hole in the micro drilling process of Inconel 718.
They stated that the hole surface roughness increased with the number
of holes regardless of the inclination of the workpiece, with an oblique
Fig. 7. Experimental setup of the study [61].
10
Measurement 201 (2022) 111757
hole having a higher surface roughness (1 μm, Ra) than a straight hole.
Vates et al. [92] optimized the process parameters using an electro
discharge drilling machine to drill tungsten carbide material using the
Taguchi L9 approach. Ouyang et al. [93] done the drilling experiments of
CFRP material with Picosecond laser cutting technique. Bhat et al. [94]
studied the effects of composite material thickness and machining pa­
rameters like feed and speed rate on the damages in GFRP composites
during drilling. As a result of their studies, the thickness was obtained as
the most important parameter that affects the overall performance index
that defines the machining quality of the drilled hole and contributes
21.30% to the total variance. They stated that the increase in thickness is
only suitable for push-down delamination and degrades delamination
and surface roughness by peeling. In addition, they found that the
developed regression model was in high agreement between the esti­
mated and experimental values, with a mean error of only 6.01%. Neo
et al. [95] studied deep hole drilling of Inconel718 material using a
PCBN gun drill. They found that the surface quality of the holes drilled
with PCBN gun drills was better than those drilled with conventional
carbide gun drills. Liu et al. [96] tested the reinforcement and
machining of integrated ultrasonic peening drilling of Ti6Al4V alloy
material to evaluate machining accuracy and surface integrity. The
schematic view of their work is given in Fig. 8. And at Fig. 8 shows about
experimental setup, Kistler dynamometer, platform with workpiece and
which is used reaming tool. Ortiz-de-Zarate et al. [97] evaluated the
surface integrity resulting from broaching of Ti64 material both exper­
imentally and by FEM analysis. Zhu et al. [98] performed the evaluation
of new tool geometries on surface integrity on the AA2024-T351/
Ti6Al4V stack. Xu and Yongfeng [99] investigated the broaching force
and the surface quality of the workpiece in broaching AISI 1045 mate­
rial. Table 4 presents the review of surface roughness and integrity
studies about hole machining.
Conclusion on the subsection: Surface roughness and integrity are
the main problems in machining operations since they demonstrate
changing structure through the surface and body. In the meantime, the
tribological behavior, wear characteristics, coefficient of friction level,
sealing, corrosion and oxidation conditions are determined by the sur­
face integrity and surface profiles. These properties need to be arranged
by operational parameters, artificial intelligence approaches, cooling
and lubricating strategies etc. but considering the narrow area like
holes, this situation become more complicate due to the closeness of the
dimensions of tool and hole. The complexity of the tool wear especially
for drill bits make this case problematic. Thus, careful monitoring of the
machining zone is highly critical for better surface properties. Rough­
ness tester and SEM photos are the broad ways of determination of the
R. Binali et al. Measurement 201 (2022) 111757

Table 3
Literature review of dimensional accuracy studies about hole machining.
Type of sensors Machining operations Process Workpiece Aim Ref.

Dynamometer, CMM SmartScope ZIP, 5-axis machining center Drilling CFRP/AA7075 Examine the drilling process [48]
image analysis system laser
Three-dimensional profilometer, SEM Hybrid (grinding and Grinding and Stainless steel 321 Investigation of grinding and electrochemical [49]
electrochemical) electrochemical hybrid process
removal
Optical microscope, FEI Nova Nano- Ultrasonic-assisted Electrochemical drill- 304 stainless steels Increasing operational efficiency [50]
SEM 450, Wyko NT9300 white light electrochemical drill- grinding
interferometer grinding machine
Tactile roughness measurement, force Honing machine Honing 20MnCr5 To improve the honing process control [51]
sensor, load cell
Digital microscope AWJ machine Drilling with abrasive Cf/SiC To studied the hole properties and formation [52]
water jet machining mechanisms of surface damages.
Mathematical equation CNC plasma bench Drilling Ti–6Al–4 V Optimization of machining parameters for [53]
roundness
Digital microscope Laser machine Drilling Cf/SiC composite Development of a new method for processing [54]
high-quality materials
Dynamometer, perthometer, infrared three-axis CNC machine Drilling and helical CARALL (carbon Comparison of drilling and helical milling for [55]
thermal camera, digital microscope, milling fiber aluminum drilling
CMM, optical microscope, SEM laminates)
Mitutoyo surftest meter CNC Abrasive water jet Drilling GFRP An investigation of the effect of process [56]
machine variables on surface roughness and
dimensional accuracy
CMM, Surface roughness tester CNC vertical machine Drilling SS410 An investigation of performance of uncoated [57]
and AlTiN coated HSS drill
Mitutoyo surftest-4 and CMM CNC Drilling EN-31 alloy Obtain to optimal setting of process parameters [58]
Vertical Machine Centre steel
SEM, Digital microscope, mEDM Drilling Inconel 718 To build empirical models for EWR, MRR, [59]
accelerometer and FE-SEM taper angle and overcut in the low frequency
vibration assisted mEDM of the Inconel718.
Dynamometer, SEM 5-axis CNC machining Drilling CFRP/Al/CFRP To studied the drilling quality of both TiAlN [60]
center coated and uncoated tools
Dynamometer, optical measurement 5-axis machining Drilling Ti/CFRP stacks Achieve a new depth-of-cut-controlled drill [50]
System, digital microscope and CMM Center structure
CMM, dynamometer and Infrared CNC vertical machining Drilling CFRP/Al Creation of a kinematic model [61]
thermography center
Vision based optical Laser Beam Machining Drilling Ti6Al4V Understanding the effect of process parameters [62]
microscope system on ovality in the LBM process
Digital microscope, laser microscope Sauer ultrasonic 80 Drilling CFRP Examination of hole integrity [63]
machine
Vibrometer, dynamometer, optical CNC machine tool Drilling CFRP Optimizing cutting parameters to ensure [64]
microscope, software ImageJ without delamination holes
Optical Laser machine Drilling Kevlar-29 FRP Determination of hole circularity and taper [65]
microscope composite angle
CMM, contact type roughness tester AWJ machine tool Drilling 304 stainless steels To studied the effect of abrasive mixtures on [66]
drilling performance with abrasive water jet.
Optical microscope Micro EDM Drilling Ti–6Al–4V Optimization of cutting parameters [67]

surface roughness and integrity. As seen, wide range of materials are
processed for improved surface characteristics with the hole machining
applications. According to the literature analysis, tool performance
improvement and parameter optimization are the selected ways for
surface quality enhancement.
4. Sensor systems in hole machining
Sensorial signals are the primary information source in data-driven
enterprises. In manufacturing industry, machining stands as the final
operation as per its main approach is about shaping the part into the
final dimensions. From this point of view, monitoring of these systems
with contemporary sensors is of great importance. TCM systems are the
key elements of such initiatives and indirect unit of such systems are
selected as the primary subject of this section. Several sensor types were
preferred in this area to observe the machining field such as dyna­
mometer, accelerometer, pyrometer, ampere meter, thermal camera,
microphone etc. This section aims to outline the practical applications of
these sensor systems in hole machining operations.
4.1. Cutting force sensor
Cutting forces are one of the parameters that express the
machinability of materials [100]. The forces occurring in machining
operations depend on many factors such as cutting tool and workpiece
material, machining conditions, cutting depth, material of the cutting
tool geometry and machining parameters [101,102]. It is a source of
information about cutting forces, temperature, vibration, chip formation
mechanics and the state of the cutting tool in the course of machining
[103]. Cutting forces affect the machined surface quality as well as the
tool life of the drills [104]. The method of measuring the cutting forces
generated during the machining operations can be classified in two
ways. The first of these is the adaptive force measurement system, which
is the force measurement method performed by analyzing the current or
electrical signals received from the control system of the machine or the
spindle to which the cutting tool is connected. Another method is to
measure the force by transducers such as strain gauges, dynamometers
and load cells placed on the workpiece or cutting tool clamps [105]. The
components of the chip removal forces corresponding to a flute during
drilling are feed force, cutting force and radial force [106]. The radial
forces that occur in each cutting edge due to the position of the cutting
edge balance each other. Therefore, only cutting and feed forces are
effective in the drilling process [107,108]. Some of the studies about
evaluating the cutting forces during machining of holes are presented in
this section of the paper. Lu et al. [109] studied a method for force
estimation in internal grinding of SiCp/Al composite materials. Schmidt

11
R. Binali et al.
Fig. 8. Schematic diagram of experiments for UPD [96].
et al. [110] conducted the relationship between cutting forces and
operational properties in the hole sub-surface region due to machining
parameters during deep hole drilling of 4140 and 304L materials. Liu
et al. [111] investigated the scale-aperture modeling of dynamic pro­
gressive failure in drilling CFRP using a conical drill-reamer set, both by
physical experiments and by the finite element method. Şirin et al. [112]
carried out drilling experiments in Hastelloy X, a nickel-based superal­
loy. The base aim of his work is to examine the effects of different
cooling methods on processing. The schematic view of their work is
given in Fig. 9 and in the figure shows, apart from the cutting force
sensor, thermal camera for measurement temperature and MQL system
are given.
Azghandi et al. [113] performed studies on shear force in conven­
tional and ultrasonic assisted drilling. In another study, Grguraš et al.
[114] made the drilling experiments of Ti6Al4V material with the help
of a robotic device. In their study, they applied the LCO2 + MQL system
from inside the cutting tool they used. And they investigated the torque
and thrust force values during drilling in dry and cooled conditions. Rey
et al. [101] studied on developing a model of cutting forces depending
on the tool geometry and machining conditions for the purpose of
control the finally quality of the hole with orbital drilling of Ti6Al4V
material. Xu et al. [115] investigated the perforation of CFRP/Ti6Al4V
stacks using the orthogonal cutting process. Pascual et al. [116] inves­
tigated delamination an axial cutting forces when drilling carbon fiber
composite materials. Merino-Pérez et al. [117] measured the effect of
cutting speed and workpiece components on the cutting forces gener­
ated when drilling CFRP composites materials. Boughdiri et al. [118]
made experiments on the effects of thrust force, torque and hole quality
of machining parameters when punching GLARE 2B laminates. Sterle
et al. [119] worked on a study on the effects of liquid carbon dioxide
cooling, cutting speed and minimum amount of lubrication on the pro­
cess outputs (thrust force, temperature and torque) in the drilling pro­
cess of 42CrMo4 steel material. Manickam and Partipan [120] studied
the effects of cutting parameters on the process outputs when drilling
AISI 317L material. Gao et al. [121] conducted the effect of longitudinal-
torsion ultrasonically assisted vibration on micro-hole drilling Ti6Al4V
titanium alloy material. Li et al. [111] studied on the drilling and
grinding of small holes using ultrasonically assisted plasma electric
oxidation grinding of Ti6Al4V titanium alloy. Baraheni et al. [122], have
studied the axial force and surface hardness of AA7075 alloy material
12
Measurement 201 (2022) 111757
used in the aerospace industry in friction and ultrasonic assisted friction
drilling processes. Pan et al. [123] made a study based on the cutting
force observer-based tool deviation compensation method for orbital
drilling of CFRP/Ti stack materials. In their study, which is used the test
platform to orbital drilling, dynamometer and workpiece with clamping
device is given in Fig. 10. Ahmed et al. [124] studied the deep hole
drilling of Inconel 718. Caitano et al. [125] investigated influence of
finishing post-treatment on margin surfaces and drill rake in the drilling
of 4144 M steel. Caggiano et al. [126] experimentally studied the dril­
ling process of Al/CFRP stacks under different drilling circumstances.
Ciecieląg et al. [127] experimented drilling experiments of glass fiber
reinforced plastic materials to detect composite defects based on drilling
signals. In another study, Yazman et al. [128] studied the effects of die
casting parameters when high speed drillability of cast AZ91 alloy.
Table 5 summarizes the hole machining papers published in the open
literature including several types of materials and operations.
Conclusion on the subsection: Cutting forces have huge impor­
tance since they determine the tribological characteristics, wear level of
cutting tool and exposition to the cutting loads. Therefore, their recog­
nition and analysis present a clear advantage in the success of hole
machining operations. Dynamometer is an effective tool to measure the
different components of cutting forces simultaneously. Main advantage
of this sensor is being downside of the cutting area which is highly
effective for sensitive measurement. However, dynamometer is highly
expensive tool compared to other sensor types. In the literature, there
are a number of dynamometer design and test approaches which need to
be considered for the young researchers. When looking at the previous
papers published in the field of hole machining, dynamometer is the first
of choice of the researchers seemingly. In addition, titanium alloys and
CFRP composites are heavily selected for this purpose. Drilling is the
most applied operation used the dynamometer as a base sensor. Devel­
oping a model, parameter optimization, lubri-cooling effect detection,
estimation are the encountered topics while using dynamometer in hole
machining processes.
4.2. Vibration sensor
Vibration refers to oscillations occurring in mechanical systems. It
adversely affects the surface of the material formed and the life of the
tool during machining operations. There are two different vibrations
R. Binali et al. Measurement 201 (2022) 111757

Table 4
Literature review of surface roughness and integrity studies about hole machining.
Type of sensors Machining Process Workpiece Aim Ref.
operations

SEM Micro-EDM Drilling and Hymu 80 (high-nickel To investigate the optimal electrode gap [78]
grinding alloy) voltage corresponding to divergent peak
currents.
Electron microscope Turning Honing 304 stainless steel Determination of the effects of ultrasonic [50]
amplitude, rotation speed and machining
time on roughness.
3D laser microscope, metallographic microscope, X-ray Milling Machine Sequential Ti-6Al-4V Improvement of hole surface integrity [79]
diffraction milling process
Thermal Vertical Drilling SS304 Investigation of the potential of Al2O3/ [80]
analyzer, surface roughness device machining center GULFCUT 56UA nano coolant for drilling.
Dynamometer, EDX, stereo microscope, scanning electron Drilling machine Deep hole A36 steel To determine the effect of ultrasonic [81]
microscope with ultrasonic drilling vibration on deep hole drilling
generator performance
Surface roughness tester Radial drilling Drilling AA-6063 Evaluating the performance of plant-based [82]
machine MQL during the drilling process
Dynamometer, light microscope, Diavite DH-8 instrument Machine centre Drilling Ti-5Al-5Mo-5V-3Cr To determine understanding of the surface [83]
roughness response of the Ti5553 for
drilling.
SEM, noncontact EDM and ECDD Drilling Nickel-based Evaluation of machining behavior between [84]
confocal interferometry 3D profiler, metallurgical superalloy ECDD and EDM for a Ni-based superalloy
microscope, X-ray stress analyser, microhardness tester, material.
tool microscope, conductivity test instrument
Optical microscopy Vertical Drilling Inconel 718 To study of drilling properties of Inconel [85]
machining center 718.
Dynamometer, microscope, laser 5-axis CNC Drilling Cf/SiC composite Study of the effects of different cutting [86]
confocal microscope and FESEM machining center parameters on hole exit defects
Dynamometer, FESEM Micro machining Micro drilling Incoloy 825 Investigation of surface integrity and [87]
centre cutting forces.
Pin gauge, dial gauge, roundness measuring instrument, Deep hole drilling Drilling Ti6Al4V Develop small diameter deep hole drilling [88]
profilometer machine machine
Dynamometer, Surface roughness tester, Vision measuring CNC vertical Drilling MWCNT reinforced To investigate the circularity error and [89]
system Machine epoxy nano surface roughness to investigate the effect
composites of machining parameters
Optical microscopy, SEM, EDX, light interferometer and Five-axis Drilling 49Fe49Co2V To investigate the drilled surface [90]
laser scanning confocal microscope machining center topography and roughness, mechanical
and metallurgical properties.
Dynamometer, interferometer, optical microscope, SEM Hybrid-μEDM Drilling Inconel 718 Evaluation of tool life, hole diameter and [91]
and X-ray diffract meter surface integrity for straight and inclined
micro-hole surface
Surface roughness tester electro discharge Drilling tungsten carbide Optimizing process parameters [92]
drilling
Scanning Galvanometer, CCD Camera CNC drilling Drilling CFRP Comparison of laser and traditional [93]
machine drilling technique
Taylor Hobson Surtronic 3 +, CANON EOS 1200D Vertical Drilling GFRP composite Optimizing process parameters [94]
machining center
Rotor sensor, digital microscope, CMM, surface profiler Deep hole drilling Drilling Inconel 718 Improve polycrystalline cubic boron [95]
machine nitride tipped gun drill
Laser microscope, SEM, 3D white-light interference CNC machining Drilling Ti-6Al-4V To realize precision machining integration. [96]
surface topographer, contact type surface roughness center
instrument, Nano indenter, dynamometer, internal
micrometer and XRD
Profilometer, dynamometer, SEM Hydraulic Broaching Ti64 Validation of the FEM model on the surface [97]
broaching integrity printouts
machine
Dynamometer, a 3D laser scanning microscope, SEM, Vertical Drilling AA 2024-T351/ Understand the influence of tool geometry [98]
Veeco-NT9300 System machining center Ti6Al4V stack on machining properties
Force sensor, micro camera, Microscope, roughness tester Broaching Broaching AISI 1045 Improving the cutting performance of [99]
machine broaching tools

that occur during the process. These are forced vibration and sponta­
neous vibrations. While forced vibration occurs due to mechanical
movements of the machine tool, spontaneous vibration occurs due to
chip removal. The traces left by the cutting tool on the machined sur­
faces are also caused by vibration. This situation is called scratching or
grazing. The chattering problem is undesirable because it negatively
affects the surface quality, measurement accuracy and tool life. Owing to
the increased cutting force in consequence of vibration and chatter,
breakage may also occur in the elements of the cutting tool or machine
tool. Therefore, machining parameters should be selected under the
vibration and chatter limit. In drilling operations, as the tip of the tools
wears, the cutting force increases, the cutting tool breaks and creates
fluctuations between the materials [129]. Thus, vibration occurs. An
accelerometer can be first candidate for using in vibration measure­
ments. These accelerometers are very suitable for use in monitoring
cutting tool wear due to certain characteristics. These properties do not
affect the rigidity and dynamic properties of the drilling system if the
mass of the accelerometer is very small compared to the mass of the
measurement location. Regardless of the workpiece or cutting tool, they
can be easily mounted close to the cutting process. It is possible to get an
idea of the wear status of the cutting tool when the levels of vibration
signals are observed. The spectrum of vibration signals collected in the
drilling process can be used to designate what type of wear is happening
on the drill bit. According to the above mentioned issues, vibration

13
R. Binali et al. Measurement 201 (2022) 111757

Fig. 9. Experimental setup of the cutting forces adopted to drilling machine [112].

Fig. 10. The test platform for orbital drilling [123].

monitoring in machining operations and especially hole machining is
critical [130]. Some of the studies regarding of this subject is given in the
following. Kang et al. [131] studied the lens ultrasonic vibration assisted
laser processing system for drilling of AISI304 stainless steels. Si et al.
[132] performed a study on the rotating sensing method in deep hole
drilling depending multivariable simultaneous compression conversion
of vertical dual channel vibration signal while drilling 45 steels. Jiménez
et al. [133] worked on a model to predict low frequency radial vibra­
tions in pilot hole drilling. Uekita et al. [134] investigated the chatter
identification method in deep hole drilling for a steam turbine rotor by
combining short-term spectral kurtosis and fourier transform analysis.
Yang et al. [135] worked to create a new analytical model that predicts
the frequency correction and vibration amplitude, drill working angle,
torque and cutting forces when drilling Ti-6Al-4V alloy material. Li et al.
[136] worked on the experiments on the quantitative and observation
evaluation of bubble behavior in micro hole drilling of SUS304 steel. The
schematic view of the system is given in Fig. 8. In another study by Ni
et al. [137] used green additive water-based cutting fluids were evalu­
ated in broaching. Cui et al. [138] performed experimental studies to
predict the delamination of CFRP materials based on Multi-sensor data.
Ma et al. [139] evaluated tapping stability using the frequency domain
method. Jáuregui et al. [140] worked on time–frequency and frequency

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R. Binali et al. Measurement 201 (2022) 111757

Table 5
Literature review of cutting forces studies about hole machining.
Type of sensors Machining operations Process Workpiece Aim Ref.

Dynamometer, microscope Milling Hole machining SiCp/Al Establishing an analytical grinding force model [109]
composite
Third piezoelectric sensor, strain Deep hole drilling Boring AISI 4140 and To understand the relationship between operating forces [110]
gauges, stationary roughness tester machine 304L and operational properties in the hole sub-surface region.
Scanning electron CNC milling center, FEM Drilling with CFRP It is the simulation of dynamic progressive failure [111]
microscope, dynamometer, tapered drill- behaviors and the determination of structural
reamer mechanical responses.
Dynamometer and infrared camera Vertical machining Drilling Hastelloy X Determination of the effect of mono and hybrid nanofluid [112]
center materials and added surfactants on machinability
performance.
Dynamometer Universal milling Drilling X20Cr13 Comparison of conventional drilling and ultrasonic [113]
machine assisted drilling
Dynamometer Anthropomorphic robot Drilling Ti6Al4V Investigation of drilling process of Ti6Al4V material with [114]
KUKA KR 150–2 the help of LCO2 + MQL
Dynamometer CNC machining centre Orbital drilling Ti6Al4V Develop a cutting force model. [101]
Dynamometer, toolmaker’s Five-axis CNC machining Drilling CFRP/ Interpretation of drilling using the orthogonal cutting [115]
microscope, white-light center Ti6Al4V process.
interferometer and SEM
Rotary dynamometer, optical NC control milling Drilling CFRP Comparison of the results obtained using different [116]
microscope parameters
Dynamometer, infra-red camera, SEM Three-axis CNC machine Drilling CFRP To study the effect of consecutive hole number and [117]
and X-Ray cutting speed on cutting forces
Dynamometer, surface instrument, CNC Drilling GLARE 2B To study the effect of machining parameters on cutting [118]
CMM and aerosol spectrometer milling machine laminates forces and torque variations.
Dynamometer, infrared pyrometer and 6-axis robot (KUKA Drilling 42CrMo4 To examine of the effect of cutting parameters on process [119]
digital microscope KR150) outputs in drilling chromium-molybdenum steel
Dynamometer, surface tester Radial Drilling machine Drilling AISI SS317L Optimization of drilling parameters [120]
High-speed camera, dynamometer, CNC Machining Center Drilling Ti6Al4V Longitudinal-Torsion Ultrasonic Assisted Drilling process [121]
laser displacement sensor and digital review
microscope
Dynamometer, ellipsometer, SEM-EDX, Three-axis CNC machine Drilling and Hole Ti6Al4V Development of a new grinding technique for drilling [111]
tool Grinding with a combination of plasma electrolytic oxidation and
ultrasonic assisted grinding.
Dynamometer, Micro Vickers Lathe machine, FEM Drilling AA7075 Investigation of the application of ultrasonic vibration [122]
Hardness tester
Dynamometer Orbital drilling system Orbital drilling CFRP/Ti Radial cutting force estimation. [123]
stacks
Optical microscope and dynamometer CNC drill press Drilling Al/CFRP Investigating thrust and torque signals [126]
stacks
Dynamometer Vertical Drilling CFRP Detecting defects in the sounding signal. [127]
machining center
Dynamometer Vertical Drilling AZ91 alloy Investigation of different casting parameters. [128]
machining center
Dynamometer, CMM, optical Gun drilling Drilling Inconel 718 To understand the dynamic behavior of gun drilling [124]
microscope Machine
SEM, dynamometer CNC vertical machine Drilling SAE 4144 M To training a tool surface finish under different [125]
center machining times.

Fig. 11. Schematic of experimental equipment [136].

15
R. Binali et al. Measurement 201 (2022) 111757

analysis of vibration signals and cutting force for TCM. Balaji et al. [141]
evaluated the optimization of cutting parameters for drilling TI6Al4V.
Ni et al. [142] evaluated the broaching of AISI 1045 steel with the MQL
system (Fig. 11). The setup of the experimental setup and the connection
of the sensors (high-speed camera, current and laser sensor) used in the
study to the oscilloscope and computer are shown in Fig. 11. Table 6
presents review of vibration studies about hole machining.
Conclusion on the subsection: Vibration is a main problem which
plays a role on surface degradation and fast-developing tool wear in
machining operations. Meanwhile, vibration becomes a primary issue
during hole machining mostly due to the elongated tool holder espe­
cially working on deep holes. Such situation produces incredibly high
radial forces on the cutting tool which may result in rapid breakage or
failures. To best of our knowledge, many studies have been done to
suppress the chatter vibrations in deep hole drilling processes based on
tool holder design. The second approach to solve this problem is using
accelerometers around the cutting zone. According to the latest studies
in this field, industrially important materials such as titanium alloys,
carbon steels and stainless steels are the focused material types operated
under utilization of accelerometers and vibration detectors. Delamina­
tion detection, tool wear detection, lubrication performance and anal­
ysis of oscillation conditions are the prominent subjects of vibration
measurement during hole machining according to the literature review.
Even a little, some other processes are taking attention in terms of using
vibration data in this field namely broaching and polishing.
4.3. Acoustic emission sensor
Acoustics studies include the control of vibrations and noise that
cause noise. The measurement of wear on the tools is made by different
methods such as acoustic emission, cutting forces and vibration mea­
surement. Acoustic emission can be defined as the sudden release of
energy by materials under stress caused by one or more problems,
producing temporary elastic waves and temporary mechanical vibra­
tions. The release or generation of the emission requires voltage or an
excitatory sensor. The energy levels of the emission vary from disloca­
tion movements in metallic materials and energy levels that cause
destructive cracking of structures. Instruments that perform acoustic
emission monitoring listen for crack initiation or propagation, noises
caused by corrosion and dislocation movements. However, it cannot
perform the listening of non-growing cracks. Acoustic emission infor­
mation is highly important issue especially thinking about the
machining of narrow holes since such operations are difficult due to the
chip removing mechanism and vibrations. The following lines summa­
rizes the studies about the measurement of acoustic emission applica­
tions utilized in the hole machining. Ferrari and Gómez [143] studied
acoustic emission when drilling SAE 1040 steel to evaluate the degree of
tool wear and the quality of the product’s finish. Duo et al. [144]
analyzed the machining conditions where a given roughness level is
expected to meet certain requirements as a result of drilling 35CrMo4
steel material on a vertical milling machine. Zhang et al. [145] have
studied the effect of apex offset inconsistency on hole flatness deviation
in deep hole drilling of Inconel 718. Möhring et al. [146] conducted
drilling experiments of FRP/Al stacks using acoustic emissions. Duo
et al. [147] investigated drilling process monitoring. In another study,
Duo et al. [148] performed 35CrMo4 drilling experiments to predict tool
wear in drilling. In their study, they evaluated the statistical properties
of the results derived from multiple signals. Klocke et al. [149] studied
the emitted frequency owing to the wear on the side surface of the
cutting tool Rishikesan et al. [150] conducted the damage during dril­
ling of GFRP composites using acoustic emission (Fig. 12). In Fig. 12,
information about the fixing method of GFRP sandwich composites, the
location of the acoustic emission sensor and dynamometer, and the
optical appearance of the workpiece after processing are given. Table 7
presents literature review of acoustic emission studies about hole
machining.
Conclusion on the subsection: Acoustic emission sensors are easy
to integrate around the cutting zone and highly sensitive to the
machining mechanisms that triggers the sensor signal such as chip
breakage, chip production, tool wear, tool breakage etc. Moreover, its
main advantage is to sense the large energy discharge during plastic
deformation. Therefore, it is possible to monitor the close area of hole
during cutting material. That’s why the application of such sensorial
data will be useful to protect the cutting tool before breakage and fail­
ure. Also, some events like chip tangling may be eliminated before it
happens which is important to preserve the hole surface. Seemingly,
acoustic emission integrated works in the last years are about only
drilling operations. It should be noted that acoustic emission sensor is

Table 6
Literature review of vibration studies about hole machining.
Type of sensors Machining Process Workpiece Aim Ref.
operations

Vibration device and amplitude meter Vertical Laser polishing 304 stainless Applying ultrasonic valuation laser processing [131]
milling center and drilling steel to a new lens
Current sensor Deep hole drilling Drilling AISI 1045 Develop a whirling detection method [132]
machine
Dynamometer Three-axis Drilling Al7075-T6 To analyze the equation of motion of the drill in [133]
machining center the frequency domain.
Accelerometer Deep hole drilling Drilling Steam turbine Developing a new TCM technique [134]
machine rotor
Dynamometer, eddy current sensor Three-axis CNC Drilling Ti-6Al-4V To create estimate model of torque and cutting [135]
machine force in drilling process
High-speed camera, laser sensor, oscilloscope, current Micro EDM Drilling SUS304 Investigating micro EDM bubble behavior [136]
sensor machine
Laser doppler vibrometer, machine vision system CNC vertical Drilling TI6Al4V Study of the effects of drilling parameters on [141]
Machine acceleration of drill vibration speed
High-speed microscope, kinematic viscometer, Broaching machine Broaching AISI 1045 Development of environmentally friendly [122]
roughness tester and vibration sensor cutting fluids
Pressure sensor, high-speed microscope, e Horizontal internal Broaching AISI 1045 To examine the lubricating performance of [137]
metallographic microscope, kinematic viscometer, broaching water fundamental cutting liquids in broaching
vibration sensor machine
Infrared camera, laser vibrometer, dynamometer, Vertical CNC Drilling CFRP Developing a data-driven method to predict [138]
optical microscope machining center delamination
Dynamometer, acceleration sensor Vertical CNC Tapping AISI1045 Analyzing tapping stability [139]
machining center
Accelerometer, dynamometer Micro-milling Drilling AISI 1045 Estimating the tool state of the high speed micro [140]
center milling process.

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R. Binali et al. Measurement 201 (2022) 111757

Fig. 12. Schematic representation of experimental set-up [150].

Table 7
Literature review of acoustic emission studies about hole machining.
Type of sensors Machining Process Workpiece Aim Ref.
operations

Dynamometer 5-axis machining Drilling DA718 and C45 It is an estimation of tool wear status based on acoustic [149]
and acoustic emission centre emission signals.
Acoustic emission, load cell, Milling machine Drilling SAE 1040 steel It is aimed to distinguish the different wear conditions [143]
of the drill bits during the process.
Acoustic emission sensor, dynamometer and Vertical milling Drilling 35CrMo4 steel Examining hierarchical clustering methods [144]
triaxial accelerometer machine
Acoustic emission sensor, dynamometer, stereo 3-axis CNC Drilling GFRP honeycomb Investigation of the effects of various acoustic emission [150]
microscope machine sandwich composite properties on delamination.
3D microscope, dynamometer, CMM, acoustic 5-axis CNC Drilling Inconel 718 To study the impact of apex offset inconsistency. [145]
sensor machine system
Acoustic emission sensor, high speed camera 5-axis machining Drilling FRP/Al stacks Effect of drill point angles and tool wear on acoustic [146]
center emission
Acoustic emission sensor, accelerometer, Vertical milling Drilling 35CrMo4 Sensory data collection in drilling processes for more [147]
dynamometer, 3D confocal profilometer machine robust decision-making and faster paradigms
Profilometer, macroscope, dynamometer, Vertical CNC Drilling 35CrMo4 Comparing the most epidemically used signals for wear [148]
acoustic emission milling machine detection in terms of machine learning.
sensor, accelerometer

used generally with other sensors such as dynamometer and acceler­
ometer which shows the situation that it is preferred as a secondary
information source. In addition to that, acoustic emission signals were
utilized broadly for tool wear detection in drilling processes.
4.4. Cutting temperature sensor
The heat and temperature caused by the chip removed from the
materials during machining includes the energy necessary for the chip to
be removed from the material, the friction between the removed chip
and the cutting tool, and the friction there among the cutting tool and
the workpiece surface [151]. Some of the heat and temperature gener­
ated is thrown out with the sawdust removed from the material, and the
remaining heat and temperature is transferred to the cutting tool and
workpiece. The temperature rise occurs with the heat transferred to the
tool and the workpiece and causes the cutting tool to wear. This causes a
reduction in tool life [152]. It is important to control this temperature,
which occurs for the ideal manufacturing process desired. Inability to
control the temperature causes undesirable changes in the chemical
structure of the workpiece, as well as reducing the life of the tool. Since
drilling is also a machining method, these situations are completely
valid. Thermal camera and thermocouples are widely used to measure
the temperature generated during cutting. Koklu and Coban [153]
conducted drilling experiments on AZ31 alloy in dry and cryogenic
circumstances at different machining parameters. The effects of dip
cryogenic application on temperature, tool wear, thrust force and chip
formation during drilling were studied. Han et al. [154] studied the
modeling of geometric thermal distortion caused by reaming, tapping
and drilling. In his study, Bilgin [155] performed friction drilling tests
for AA7075T6 alloy material in dry, MQL, heat and heat + MQL process
conditions. Rodríguez et al. [156] evaluated the perforation of CFRP-
Ti6Al4V stacked material using CO2-cryogenic cooling by tempera­
ture, power consumed, hole quality and surface quality. Pal et al. [157]
applied minimal amount of lubrication technique with Al2O3 blended
vegetable oil fundamental cutting fluid in their studies. In their experi­
mental studies, they analyzed the effects of various cooling-lubricant
media on the performance of the AISI 321 drilling operation on the
process output. Guba et al. [158] worked to minimize the errors that
occur during deep hole drilling. Bonnet et al. [159] worked on the
progress of a multi-scale and combined cutting model for drilling
Ti6Al4V titanium alloy material. Shao et al. [160], investigated the ef­
fects on interface temperature and surface integrity in ultrasonically
assisted drilling of CFRP/Ti stack materials (Fig. 13). In the Fig. 13 are
given information, about the measurement area, laser micrometer, IR
camera, Kistler dynamometer and fixing methods thermocouples.
Ahmed et al. [161] investigated of cryogenic cooling effect in

17
R. Binali et al.
Fig. 13. (a) The details of ultrasonic shank and (b) experimental setup [160].
reaming Ti6AL4V material. Xu et al. [135] performed a comparison
study between conventional and vibration assisted drilling of CFRP/
Ti6Al4V stack materials. In their study, Rinschede et al. [162], investi­
gated the use of low temperature emulsion in the drilling of Inconel718
alloy. Seeholzer et al. [163] evaluated the temperature changes in the
carbon fiber reinforced polymer material owing to hot aluminum chip
interactions also the maximum temperatures in both individual stack
components by examining the effect of divergent cooling strategies on
chip transport quality and machining temperatures in single-drilled
CFRP/Al piles. Alonso et al. [164] studied drilling experiments of pol­
ycarbonate PC 1000 material. Onawumi et al. [165] studied drilling of
CFRP/Ti stacks. In another study, Pang and Wang [166] investigated the
performance of drilling with different micro texture drilling tools of
Inconel 718. Felinks et al. [167], conducted the effect of temperature on
front face flow drilling and thread forming in AZ91 and AlSi10Mg alloys.
Zhang et al. [168] conducted the drilling performance of co-cured
CFRP/invar material. Karabulut and Bilgin [169] investigated the fric­
tion drilling behavior of AA 7075T6 aluminum and AZ31B magnesium
alloy materials dry and under minimal lubrication. Zhu et al. [170]
evaluated the tool temperature divisions in drilling of AA 2024-T351.
The transfer of the data obtained from the experimental setup, cutting
tool and workpiece material they used in their work is given in Fig. 14.
Table 8 summarizes the details of cutting temperature measurement-
based tool condition monitoring systems for hole machining processes.
Conclusion on the subsection: Temperature measurement can be
18
Measurement 201 (2022) 111757
done by distant sensors like thermal camera or close sensor which affect
the easiness due to the integration of thermocouple is an issue that takes
time and requires expertise. Therefore, their effectiveness needs to be
evaluated since the thermal shocks may affect the tool wear and chip
breakage mechanism in the hole considerably. Seemingly, mentioned
sensors along with pyrometer are preferred for temperature measure­
ment goal according to literature analysis. Reaming, tapping, deep hole
drilling and thread forming are also considered for the utilization of
temperature sensors according to state of art review. Measurement of
thermal effects, comparison of dry and lubricating areas in terms of
temperature gradient, the general view of temperature distribution are
the main subjects according to the literature review. Determination of
temperature level is of great importance thanks to its correlation with
the tool wear mechanisms and failure. That’s why, it’s logical to inte­
grate or use a sensor based on this phenomenon for improved cutting
environment.
4.5. Current/power sensor
The current/power in the machining systems is correlated with the
cutting forces which represents high importance since it’s related with
the exposure of the cutting tool. The more the cutting tool experience,
higher cutting forces are required and it’s directly increasing the
required power. Such situation may be a problem due to the possibility
of chatter vibrations, low surface quality and fast developing cutting tool
R. Binali et al.
Fig. 14. Tool-foil thermocouple system [170].
wear. When thinking about the hole machining processes, narrow area
in these bodies make difficult to remove the chips safely. Therefore, it is
important to integrate effective cutting tools which are capable of
removing the material quickly. Therefore, it is imperative to protect the
cutting tool from these effects with preserving it from excessive wear.
Also, high cutting power is one of the reasons of high costs which makes
is it a sustainability problem. Due to these reasons, tool condition
monitoring utilized from hole machining operations is a critical issue.
From this point of view, the following papers were selected to summa­
rize this case. Teimouri et al. [171], evaluated the drilling process of
AISI 1045 steel material based on min. energy consumption and desired
work quality. Shah et al. [172], evaluated the life cycle of the Inconel
718 drilling. Yoon et al. [173], investigated processing parameters for
cost and energy savings in micro scale drilling of PCBs. Shah et al. [174],
conducted the drilling of Ti6Al4V alloy using thrust force, tool wear,
hole quality parameters, power consumption, microhardness of
machined surface and cryogenic coolants. And their work is used
experimental setup, measurement thrust force and power consumption
in the course of machining and analysis after machining are given in
Fig. 15. Wang et al. [175], investigated a study on predicting tool wear
and energy consumption in drilling operations. Sidhu et al. [176], have
studied the optimization and modeling of the active energy consumption
of the machine tool during the drilling of ST52.3 alloy steel material.
Pramanik et al. [177], investigated burr formation, active maximum
power, circularity and diameter error, cylindricality and surface
roughness in the course of drilling of 6061-aluminum alloy using
different cooling methods such as dry, liquid nitrogen, air cooling and
MQL at different machining parameters. Pal Singh and Singh [178]
investigated the effect of cryogenically treated instrument electrode in
the course of electric discharge drilling of Inconel 800 material. The
effects of discharge current, pulse opening time, tool electrode speed and
gap voltage on electrode wear rate, radial overcut and material removal
rate were investigated. Ji et al. [179], conducted the effects of cooling
methods on power consumption in drilling CFRP/Ti6Al4V stack mate­
rials. Khanna et al. [180], evaluated the power consumption of cutting
liquids for drilling VT20 titanium alloy material. Considering the above
summarized literature, Table 9 outlines the studies based on current/
19
Measurement 201 (2022) 111757
power measurement in tool monitoring systems about hole machining
processes.
Conclusion on the subsection: Current and/or power detection is
an important case especially for determination of tool wear situation
since there is a relationship between cutting force-required power-fric­
tional force and tool wear. However, cutting force measurement is much
more effective to this goal. Main drawback of this type of sensor is being
distant from the target place which reduces its sensitivity and efficiency.
On the other hand, such data can be evaluated to calculate the energy
consumption and it is highly critical to measure total machining costs.
When looking at the literature analysis on energy consumption during
hole machining processes, several initiatives can be seen on the mini­
mization of power/energy with various approaches such as optimizing
lubricating conditions, development a model and optimizing cutting
parameters. Since this topic is related with environmental impact, sus­
tainability and green manufacturing are the main topics that can be
handled for this issue. Seemingly, only simple drilling operation was
considered in the previous studies for evaluation of energy consumption
for several materials i.e., Inconel 718, Ti-6Al-4V, Al alloys, composites
and carbon steels.
4.6. Sound sensor
Sound is a natural result of machining operations which represents
important issue due to the high levels of this source refers to bad
machining quality. Main reason of this is the requirement of high cutting
forces produces elevated sound. However, such sensors are not so much
effective compared to other types of sensors in the tool condition
monitoring systems. One of the reasons of this is the diversity of the
sounds in the cutting area. Namely, chip breakage, chip formation, wear,
chatter produces different levels of sound which make is hard to catch
and separate. Therefore, acoustic emission signals become more popular
and effective way. There are a few papers about the sound application in
tool condition monitoring systems. Kimmelmann et al. [181] analyzed
the drilling of CFRP-aluminum stacked materials using acoustic emis­
sion. In another study, Liang et al. [182] worked on a new refractive
identification process using an audio signal. The schematic view of their
R. Binali et al. Measurement 201 (2022) 111757

Table 8
Literature review of cutting temperature studies about hole machining.
Type of sensors Machining Process Workpiece Aim Ref.
operations

Force dynamometer, thermal camera, digital Milling Drilling AZ31 magnesium Determination of the effects of the dipped [153]
microscope alloy cryogenic approach.
Thermocouple Drilling Drilling, AlSi7 Modeling geometric distortion caused by heat flow [138]
reaming and
tapping
Digital infrared pyrometer, potentiometer, CNC vertical mill Drilling AA7075 - T6 To achieve the optimum bushing profile [155]
surface roughness device, CMM
Infrared camera, power meter, interior Machining center Drilling CFRP-Ti6Al4V Comparison of the performance of CO2 cryogenic [156]
micrometer, microscope, confocal microscope stacks cooling with the dry drilling technique
Dynamometer, SEM, X-ray spectroscopy, Column drilling Drilling AISI 321 The aim is to investigate in detail the behavior and [157]
roughness-tester, infrared thermometer machine response parameters of various cooling media in
drilling.
Dynamometer, infrared camera, digital Deep hole drilling Deep hole AlMgSi0.5 Reducing the problems encountered in traditional [158]
microscope, Marco dynascope microscope, machine drilling deep hole drilling
Roughness tester.
Infrared camera, FEM, microscope. 5-axis machining Drilling Ti-6Al-4V Evaluation of the main properties of thermo- [159]
centre mechanical loading in drilling
Dynamometer, Thermocouples, IR Camera, laser Vertical Drilling CFRP/Ti To examine of the effect of cutting temperature on [160]
micrometer machining center surface integrity.
Dynamometer, light microscope, digital camera, Horizontal Drilling Inconel 718 Reduce thermal load [162]
pyrometer machining center
IR camera Vertical Drilling CFRP/Al-stacks Investigation of the effect of different cooling [163]
machining centre strategies n chip transport quality and process
temperatures.
Dynamometer, internal digital micrometer, 3-axis machine Drilling PC1000 Transfer of comprehensive knowledge from metal [164]
Taylor Hobson Surtronik S100-series tester, tool polycarbonate processing to polymer materials
thermographic camera
Dynamometer, thermal Universal Drilling CFRP/Ti stack Assessment hole quality and cutting forces under [165]
Camera, CMM lathe machine dry machining circumstances
SEM, scanning galvanometer, IR camera, digital Vertical Drilling Inconel 718 Comparison of different micro texture drilling tools [166]
microscope Machining Center
Thermometer, thermocouple, dynamometer NC controlled Drilling and AZ91 and AlSi10Mg The aim is to consider the effects of extended heat [167]
machining center thread forming measurement methods on face-flow drilling and
thread formation.
Temperature data storage device, SEM, laser CNC machining Drilling T700CFRP-Invar To study the drilling performance of T700 CFRP [168]
confocal microscope and CMM center alloy-T700CFRP and invar36 alloy.
Pyrometer, Mitutoyo SJ-210, CMM, CNC vertical Drilling AZ31B and AA7075- Investigating friction drilling [169]
machining T6 alloys
center
Thermocouple system Vertical Drilling AA2024-T351 Measuring the temperature distribution during the [170]
machining drilling process.
center
Dynamometer, K-type thermocouple, roughness Vertical Reaming Ti-6AL-4V Investigation of the effect of cryogenic processing [161]
checker, SEM, CMM Machining Center
Dynamometer, infrared Thermography camera, Machining center Drilling CFRP/Ti6Al4V stack Examining the LFVAD process of CFRP/Ti6Al4V [135]
digital microscope, CMM, digital microscope stacks

work is given in Fig. 16. The figure shows the connection of the sound
system to the experimental setup and the connection of the computer to
which the necessary controls are provided during the process. Table 10
outlines these studies including the sensor type, material and main aim
of the study.
Conclusion on the subsection: From the first times of machining,
sound is an information source that used for determining the abnormal
situations during metal cutting such as excessive worn tool chatter vi­
brations and associated poor surface quality. Initially, human ear ful­
filled such task and in time technological developments evolved the
period and improved sensor systems were invented. However, compared
to other sensorial devices in tool condition monitoring systems, sound
sensors i.e., microphones have important deficiencies which reveals
mostly due to the sensitivity level to the machining variations. To the
best of author’s knowledge, some successful examples utilizing the
sound measurement for improved surface integrity and wear situation
exist. Still, during the period of review of this study, it was seen that the
latest papers had no interest to the sound-based monitoring of hole
machining operations. One of the main reasons is that it is absolute that
there is need for a microphone with a wide frequency range to capture
the different types of events. More importantly, the critical point is the
capability to separate developments which produce low and high
frequencies such as breakage and cutting. It is thought that such an issue
can be solved by using multiple sensors. On the other hand, acoustic
emission sensor is a good alternative to meet these expectations which
make the sound sensor disadvantage in this field.
4.7. Multiple sensors
Single sensor systems are highly effective according to the type of the
cutting mechanism and sensitivity of the sensor type undoubtedly.
However, with the increase of the market demand in the sector in the
machining industry, little tolerances are acceptable and small errors are
expected generally [183]. So, this situation directs the sector to monitor
the cutting area with precisely using multiple sensors. Multiple mea­
surements are created between sensors that complement each other or to
monitor two different events at the same time. Main aim in using of more
than one sensor is the utilization of different types of information
sources at the same time. In addition, verification of such information
provides to understand the success rate of obtained findings. With such
approach, some details of cutting mechanism can be achieved for pro­
ducing better surface integrity or tool wear. Main issue in machining is
that there are so many parameters affecting the machining quality
[184]. Therefore, cutting tool health is of great importance because it

20
R. Binali et al.
Fig. 15. The experimental infrastructure on current/power sensor [174].
influences the surface quality and dimensional accuracy. To sustain the
machining quality through the whole operation is a significant case in
this perspective. Application of multiple sensor systems provides a clear
advantage [185]. However, undoubtedly, integration of multiple sen­
sors is expensive approach and requires more expertise in terms of
physical connection of sensors and data collection. Moreover, data
processing and evaluation is a critical issue since the noise is a big
problem especially allowing a number of sensors simultaneously. In this
perspective, there is need to consider the infrastructure of sensor sys­
tems along with their economic burden on the industry. After that,
price/performance analysis needs to be done for each sensor and
applicability of multiple sensors need to be evaluated. In this study,
there are numerous papers have been analyzed and summarized to this
point. As can be seen in the previous tables that many different sensor
combinations were tested in the literature for hole machining processes.
Figs. 9, 12, 13, 14 and 15 represents many types of multiple sensor
integration including cutting forces, acoustic emission, vibration and
current sensors.
21
Measurement 201 (2022) 111757
Conclusion on the subsection: Despite multiple sensor integration
brings many positive contributions into the machining quality, these
systems include challenging sides such as extra costs, integration time
and cost, difficulties of on-line collection of many types of sensors signal
simultaneously etc. With the support of an expert, it is thought that such
enterprises make a huge difference in the machining field especially for
making validation about the condition of the machined material and
tool wear situation.
5. Conclusions and future prospects
The following deductions can be obtained from this paper:
1. Main objectives of drilling and hole machining processes are hole
quality, tool life and chip evacuation according to the general
consensus. Such goals depend on the sustainable cutting perfor­
mance of the cutting tool which is determined by the machining
variables such as vibration, cutting forces, sound, temperature,
R. Binali et al. Measurement 201 (2022) 111757

Table 9
Literature review of current/power studies about hole machining.
Type of sensors Machining Process Workpiece Aim Ref.
operations

Energy analyzer Vertical machining Drilling Ti-6Al-4V To ensure a reinforced alternative of flood coolant [174]
center
Dynamometer and power logger PW3360 Three-axis machine Drilling GH4169 Determination of energy consumption model [175]
tool
Power Analyzer Vertical milling Drilling ST52.3 Optimizing active power consumption [176]
center Alloy
Power meter, dynamometer, CMM, CNC machine centre Drilling Al 6061-T6 To investigate the minimum amount of lubrication, compressed air [177]
microscope, surface roughness device, and liquid nitrogen cutting condition when drilling Al 6061
material
Stationary EDM Drilling Inconel 800 Increasing the energy efficiency, drilling productivity and quality of [178]
optical emission spectrometer, weight the electro discharge drilling operation
measuring
machine, MRR, EWR
Dynamometer, mathematical equation, SEM CNC machining Drilling CFRP/Ti6Al4V To study the effect of cooling methods on energy loss [179]
center plate
Energy Vertical machining Drilling VT-20 titanium Identify an energy efficient and environmentally friendly coolant [180]
and power quality analyzer, center alloy approach
dynamometer,
Dynamometer, surface roughness CNC milling Drilling AISI 1045 To investigate the effect of ultrasonic vibration and minimal [171]
tester, eddy lubrication on burr height, surface roughness and drilling force
current sensor
Dynamometer, contact type surface 3-axis vertical Drilling Inconel 718 Comparing thrust, tool wear, energy consumption and roughness at [174]
roughness, energy and power quality machining center three cutting speed levels
analyzer
Power meter, dynamometer – Drilling PCB To improve power consumption and production cost models for [173]
micro-drilling

Fig. 16. Schematic of the experimental setup [182].

power and acoustic emissions. To obtain this information quickly
and reliably, sensor systems adapted to the machining environment
are the effective tools for fast and online monitoring. Seemingly, the
integration of dynamometer, accelerometer, thermal camera, ther­
mometer etc. is helpful way to improve the quality of the surface of
the machined part, dimensional accuracy, reducing tool wear and
effective chip removal.
2. No doubt, conventional drilling process covers the large part of the
published studies according to the numbers of the sensor integrated
machine tools. This is an acceptable outcome since this operation is
necessary to produce holes on the mold parts and easy and effective
solution for the additional operations. And the literature review
shows us manufacturers and academia prefer to observe the
machining characteristics and mechanism of drilling operation with
sensor systems. Thus, it is clear that there is an enthusiasm to
understand the chip evacuation mechanism and protect the tool and
part from undesired developments. This should be a booster factor
for the people working in this area. Now, it is true that sensor systems
are expensive and require expertise but it is known that such enter­
prises compensate the infrastructure costs in time thanks to their
productivity. This can be measured by the effective usage of cutting
tool and part quality.
3. Primary problem of the hole shaping is being worked at the narrow
area which is almost same with the geometrical dimensions of the
cutting tool. During movement of the cutting tool in the workpiece,
continuous chip removing procedure need to be done owing to the
negative impacts of chips which comes from its heat capacity.
Therefore, thermocouple integration is an effective method to closely
measure the temperature of the cutting tool. Also, infrared cameras
are popular in this area for their wide-angle caption of cutting area.

22
R. Binali et al. Measurement 201 (2022) 111757

Table 10 electrical signals. Not only for the machining environment, but also
Literature review of sound studies about hole machining. for the other types of manufacturing technologies, sensors serve as a
Type of Machining Process Workpiece Aim Ref. long-winded, effective and faultless devices for improving the
sensors operations operational productivity. Therefore, it is useful to mention the pre­
Sound 5-axis Drilling CFRP Investigation [181] sented sensor systems in the perspective of Industry 4.0.
sensors, machining aluminium of burr
HFIM centre stack formation Cutting forces determine the tribological performances and wear
sensors, mechanisms tendency which has magnificent importance on the cutting ability of the
acoustic in CFRP-
emission aluminum
tool. That’s why it helps for the monitoring of the machining zone
sensor materials through digital twin method even in advanced robotic machining and
Microphone EDM Drilling Inconel 718 Investigation [182] additive manufacturing.
of the Since automatization is the main issue of Industry 4.0, detecting the
feasibility of
vibration in mechanical systems represents a real importance irre­
applying the
audio signal to spective of the place and time. Therefore, vibration monitoring,
refraction repression and damping is of great importance espeically thinking about
detection with the tendency of long tool holders in machining of the deep holes existing
EDM almost all engineering parts in the prominent sectors.
Acoustic emission sensor is capable of detecting the anomalies in the
In addition to that, pyrometer is another option for such task and working systems which include high frequency deformations like in the
gained popularity in the last years. CFRP stacks, titanium and nickel- pipes and lines carrying some fluents. The perspective of this paper is
based alloys are the most seeing materials in the applications of about monitoring the machining zone and such sensors are appropriate
temperature sensors during hole machining. It should be noted that for the determination of approaching devastating effects. This is inno­
reaming and tapping find a place in this area. vator, relatively cheap (considering its contribution) and effective way
4. Considering tool wear and part characteristics namely roughness, for protecting the machining elements.
integrity and dimensional accuracy are the ultimate aim of Current/power measurement is necessary for all initiatives who care
machining environment, it should be remunerated that there are about the sustainable development with low-cost technologies without
many studies performed in the last years about these topics. Coun­ affecting environment. All companies have to calculate the total con­
tersinking, micro drilling, blind hole drilling for tool wear, honing sumption which become critical for current/power due to the electricity
grinding and non-conventional ways for dimensional accuracy and costs presents large part of the economic burden. Industry 4.0 aims to
honing, grinding, broaching and micro drilling were the encountered give less damage to the earth sources and in this direction, collecting
processes except for the drilling about these subjects. When handling current/power data has a major influence on determining the optimum
such numbers of papers in the field, a variety of materials experi­ conditions of machine tools.
enced hole shaping operations which can be sorted as Al, Ni, Ti based Since Industry 4.0 is an initiative for big data analysis of
alloys, composites (especially CFRP), stainless steels. Seemingly, a manufacturing technologies, each information needs to be evaluated
great number of metals, alloys and composites are available for carefully. That’s why sound may be important outcome since it has in­
future studies. fluence on the human health. Therefore, operations need to be done
5. Seemingly, application of cutting force measurement in hole under optimal conditions in terms of correctly selected cutting param­
machining and drilling operations is highly popular compared with eters and cutting conditions.
other sensor types. It is understandable that cutting forces is a Temperature is a primary trigger for the tool wear in the machining
determinative factor of cutting ability of the cutting tool and affect environment. Therefore, determining the useful lifetime depends
total power and chatter tendency. Also, observing the cutting force heavily on the thermal balance of the cutting zone. Considering the
components make a huge difference since it provides important in­ importance of the surface characteristics of the machined part,
formation about the tool wear situation. On the other hand, vibra­ improvement of the health of the cutting tool gains importance.
tion, temperature and current/power measurements are quite Manufacturing operations need to arrange the variables for obtaining
popular in this area thanks to reasons as explained before. However, complete control on the whole process. Temperature represents one of
sound sensor application is very less which makes this topic highly these parameters and requires to be thought as of the main criteria.
novel while machining of any material.
6. It is noteworthy to say that except for the drilling, any hole shaping 8. Industry 4.0 directs the whole industrial systems to place in the
process is open for sensor integrated approaches. There is a few combination of data-driven, artificial intelligence supported models.
numbers of studies considering all of these operations which makes In the recent years, with the increase of complex systems including
highly potential. Experimental, numerical and analytical analyses advanced software and hardware systems, the market in the metal
are possible for such studies for wide range of materials such as al­ industry elevated their expectations in the course of developed
loys, composites, metals and plastics. Moreover, it will be highly technologies. Therefore, there is a need for intelligent systems covers
useful to consider the surface integrity characteristics and tool wear the power of computer, software, machine learning, feedback, veri­
mechanisms including microstructural images during machining of fication, error minimization and efficiency maximization. In
holes in the future work. Another opportunity to be evaluated in this machining, numerous numbers of parameters make the process
direction may be the quality improvement strategies such as utilizing highly complex. Thus, it is imperative to observe the cutting area
lubrication and cooling mediums, heat and vibration assistance, with advanced sensor systems. The place of the holes is important in
cutting tool technologies such as coatings and surface textures. any metal sector namely for aerospace, aviation, automotive, ma­
7. Industry 4.0 basically aims to combine computer, electronic and rine, medical, transportation etc. which stand as the main sources of
mechanical technologies with the help of the artificial intelligence Industry 4.0 aim in the perspective of industrial companies. That’s
approaches. In this direction, the position of the sensor technologies why the integration of smart sensor systems make a difference to
stands as the most important side of this constitution. Because, sen­ prevent the unexpected situations especially for the hole machining
sors are great opportunities to observe several environments to operations which is performed in a narrow area.
correlate the magnitudes such as pressure, current and force with 9. Future prospects: Since the drilling and hole production operationa
are widely applied in the world of machining, they have an

23
R. Binali et al.
important place for the parts manufactured by these processes.
However, the closeness and narrow area of these operations cause
some significant problems such as chip evacuation, excessive tool
wear, rapid tool breakage, burr formation, low hole surface quality,
extreme vibrations at some specific operations. That’s why, sensor
integration is of great importance especially when thinking for the
new generation materials utilized in the field of aerospace and
aeronautics. Since these types of materials are expensive and hard-
to-ensure, the operations made on them become more and more
important now. Therefore, the authors recommend that the sensorial
appliacations need to be thought deeply and obtaining expert sup­
port in the future for improving the quality of hole machining
operations.
Declaration of Competing Interest
No confict of interest.
Acknowledgment
The research leading to these results has received funding from the
Norwegian Financial Mechanism 2014-2021, Project Contract No 2020/
37/K/ST8/02795.
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