ARTICLE IN PRESS

International Journal of Machine Tools & Manufacture 49 (2009) 10701076

Contents lists available at ScienceDirect

International Journal of Machine Tools & Manufacture

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

Thrust force model for vibration-assisted drilling of aluminum 6061-T6

Simon S.F. Chang, Gary M. Bone 
McMaster Manufacturing Research Institute (MMRI), McMaster University, 1280 Main St. W., Hamilton, Ontario, Canada L8S 4L8

a r t i c l e in f o

a b s t r a c t

Article history:
Received 6 March 2009
Received in revised form
23 July 2009
Accepted 26 July 2009
Available online 5 August 2009

Vibration assistance has increasing applications in metal removal processes. This method induces highfrequency and low-amplitude vibration in the feed direction during cutting, and has the potential to
reduce cutting forces leading to improved surface quality and reduced tool wear. Note that this cutting
process is distinct from ultrasonic machining. This paper presents a thrust force model to predict the
thrust force during vibration-assisted drilling of aluminum 6061-T6. This model incorporates plowing
force and strain rate-dependent shear strength to provide more accurate predictions than the existing
model. The results of 72 drilling experiments with TiN-coated standard twist drills are reported. The
predictions from the developed thrust force model are compared with the experimental results. The
comparison demonstrates that the maximum deviation between the predictions and the averaged
values of the experimental measurements is 20% using the existing model and only 7% using the
proposed model.
& 2009 Elsevier Ltd. All rights reserved.

Keywords:
Drilling
Metal cutting
Vibration assistance
Ultrasonic assistance
Vibration-assisted drilling
Ultrasonic assisted drilling

1. Introduction
Conventional metal cutting methods, such as drilling, produce
relatively high cutting forces and low machined surface quality.
High cutting forces generally increase tool wear, and reduce
machined surface quality. This directly affects the post-processing
efforts such as surface nishing and deburring, leading to
increased production cost. There are various methods to reduce
tool wear and improve surface nish. These include using a
special coating on the tool; changing (typically reducing) the
material removal rate (MRR); or even laser-assisted machining,
which alters the mechanical properties of the workpiece material.
One recent and promising technique is known as ultrasonic
assisted or vibration-assisted machining.
Vibration-assisted machining is a pure mechanical process that
does not require sacricing MRR or altering the mechanical properties of the workpiece material. This technique typically induces
high-frequency (41000 Hz) and low-amplitude (o0.015 mm)
vibration in the feed direction of a cutting process. It has been
shown that this technique can reduce thrust force and improve
surface quality. One application of vibration-assisted machining is
vibration-assisted drilling (VAD) [15]. We have previously shown
that under preferable vibration conditions, the thrust force can be
reduced by VAD, while poor choice of vibration conditions can
result in increase in thrust force [1]. Modeling and predicting
thrust force is important for nding these preferable conditions.

 Corresponding author. Tel.: +1 905 525 9140x27591; fax: +1 905 572 7944.

E-mail address: gary@mcmaster.ca (G.M. Bone).

0890-6955/$ - see front matter & 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2009.07.011

In general there are two methods to predict thrust force: nite

element modeling and analytical modeling. This paper presents
the development of an analytical thrust force model for VAD
that extends the existing model and provides more accurate
predictions.
Analytical thrust force models for conventional drilling are
well established. They include work by Wiriyacosol and Armarego
[6], Armarego and Wright [7], Watson [8,9], Elhachimi et al.
[10,11], and Lopez de Lacalle et al. [12]. However, due to the
dynamic nature of VAD, these models cannot be directly applied.
Wang et al. [13] analyzed the instantaneous uncut chip thickness
to model the thrust force and torque in VAD under different
vibration frequencies. Zhang et al. [14] used a similar approach to
study VAD under different vibration amplitudes.
Other related cutting force models include the dynamic cutting
force model with the presence of regenerative vibrations or
chatter vibrations. Altintas [15] presented the dynamics of the
general metal cutting process. Budak and Altintas [16,17] studied
and modeled the dynamic cutting forces for milling with chatter
vibrations. Their studies modeled the variation of uncut chip
thickness by analyzing the instantaneous tool location and the
prole of the machined surface. Li and Li [18] modeled the
dynamic cutting forces for milling by modeling the variation of
uncut chip thickness and strain rate-dependent shear strength.
Roukema and Altintas [1921] presented the modeling of the
dynamic cutting forces for drilling by modeling the variation of
uncut chip thickness. Wu [22], Ismail et al. [23], Chandiramani
and Pothala [24], and Moufki et al. [25] modeled the dynamic
cutting force with the presence of plowing. The plowing forces are
modeled analytically by determining the displaced volume of the

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2W0

Nomenclature

mc
hf, hl
Tk
zt; z_ t
V
D
DVi

b0
2p
W

lnd

gnd
fnd

Zd
ri
F

g
Dli

zmax(y)
M
Ddk
Fpt, Fpx
Fl,C, Fl,T
DPi

axial/dynamic uncut chip thickness (mm)

axial location of segment k (mm)
axial displacement/velocity (mm, mm/s)
cutting velocity (mm/s)
diameter of the drill (mm)
displaced volume (mm3)
drill helix angle (rad)
drill point angle (rad)
drill web thickness (mm)
dynamic friction angle (rad)
dynamic normal rake angle (rad)
dynamic shear angle (rad)
dynamic feed angle (rad)
effective radius of the ith element (mm)
feedrate (mm/rev)
ank clearance angle (rad)
length of each segment (mm)

y
Dy

ti
fsp
n
e; e_
t
k
Dw
A
f

workpiece. Lee and Altintas [26] and Wang and Zheung [27]
modeled the plowing force empirically, and veried that plowing
force can be signicant.
The prior model of VAD ignored both the plowing force
component and the strain rate dependence of the material. This
paper presents a novel thrust force model for VAD that
incorporates these two factors. Our modeling approach is
consistent with the approaches used in the modeling of dynamic
cutting force in metal cutting with the presence of chatter
vibrations discussed above. It will be shown that by modeling
the dynamic uncut chip thickness alone as is done in the prior
VAD force model, the model fails to predict the thrust force for
VAD accurately, while the proposed model improved the accuracy
of the force predictions and the prediction of the favorable
vibration condition that minimizes thrust force. In Section 2, the
theoretical development of the model is presented. In Section 3,
comparisons between model predictions and experimental measurements are presented. Conclusions are given in Section 4.

length of the chisel edge (mm)

mean coefcient of friction of the toolwork interface
maximum depth of removed material (mm)
number of elements on each cutting lip
plowing depth (mm)
plowing force in thrust and horizontal direction (N)
principle cutting force (N)
resultant thrust force for the ith element (N)
rotational angle of the drill (rad)
rotational difference between each segment (rad)
shear strength (MPa)
specic plowing force (N/mm3)
spindle speed (rev/s)
strain, strain rate (s1)
time (s)
total number of segment on each element
width of each segment (mm)
vibration amplitude (mm)
vibration frequency (Hz)

To determine the axial uncut chip thickness, which is critical to

estimate cutting forces, it is necessary to monitor the maximum
depth of removed material at the rotational location of interest,
zmax(y). Transforming the independent variable from time (t) to
rotational angle of the drill (y) by substituting y 2pnt into
Eq. (1) gives
 
Fy
fy

3
zy A sin
n
2p

zmax(y) can be estimated by monitoring the axial location of the

cutting lips prior to the current instant. For a two-ute drill, where
there are two cutting lips at p radians away from each other, all the
axial locations of the cutting lips prior to current instant are equal to
z(yqp), where q is a positive integer (see Fig. 1). Therefore, the
maximum axial location of the cutting lips prior to the current
instant, i.e. the depth of the materials immediately in front of the
cutting lips at the current instant zmax(y) equals
zmax y zy  mp

2. Thrust force model

zy  mp4zy  m 1p

The effective (also known as dynamic) cutting geometries of a

drill vary with radius. Therefore a drill is typically divided into
elements along the cutting lips direction and the elements are
analyzed individually using a conventional mechanistic cutting
model. The total thrust force is obtained by summing all of the
thrust force components of the individual elements [612].
Following the methodology of the dynamic cutting force modeling
[1327], the instantaneous uncut chip thickness for VAD can be
estimated by studying the instantaneous displacement and
velocity of the tool. The displacement equals the summation of
the displacement due to the feed, Fnt, and the displacement due to
the vibration, A sin(2pft), as follows:
1

where A and f are the vibration amplitude (mm) and frequency

(Hz), respectively; F is the feedrate (mm/rev); n is the spindle
speed (rev/sec); and t is the time (s). Similarly, the instantaneous
velocity is
z_ t 2pfA cos2pft Fn

where m is the minimum positive integer that satises the

expression

2.1. Instantaneous axial uncut chip thickness

zt A sin2pft Fnt

1071

Fig. 1. Schematic of determining axial uncut chip thickness.

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S.S.F. Chang, G.M. Bone / International Journal of Machine Tools & Manufacture 49 (2009) 10701076

For the example shown in Fig. 2, zmax(y) z(yp) and m 1.

The axial uncut chip thickness hf therefore equals

zy  zmax y if zy4zmax y
6
hf
0
otherwise
The dynamic uncut chip thickness hl can then be calculated by
analyzing the drill geometry as in [69]:
hl hf sinp cosz=2

where

z tan1 tano cosp

o sin1

 
W
ri

In Eqs. (7)(9), p is the drill point angle, W is the drill

web thickness, and ri is the effective radius of the ith element
(see Fig. 3).
2.2. Plowing force model
Because of the oscillation of the drill during VAD, a wavy
machined surface is produced after each half revolution of the
drill. When the cutting edges engage the workpiece again,
plowing can occur, as shown in Fig. 4. If the volume of the
Fig. 4. (a) After the rst cut (half revolution for a two-ute drill), a wavy machined
surface is formed. (b) In subsequent cut, the ank surface of the drill may come in
contact with the machined surface (even at multiple locations), causing plowing of
material.

workpiece displaced by the tool is known, the plowing force can

be estimated. Based on the analysis by Wu [22], the resulting
forces for the ith element are

Fig. 2. Schematic of determining zmax(y) of the tool.

Fpt fsp DVi

10

Fpx mc Fpt

11

In Eqs. (10) and (11), Fpt and Fpx are the plowing force components
in the thrust and horizontal directions, respectively; fsp is the
experimentally determined specic plowing force; DVi is the
displaced volume; and mc is the mean friction coefcient of the
toolwork interface. DVi will now be estimated by considering the
tool prole and the maximum depth of the machined surface.
The tool prole can be modeled by dividing each drill element
into small segments along the drill ank direction. Fig. 5 shows
the difference between the drill elements and the segments. The
axial location of segment k on each drill element can be calculated
using
Tk zy 

kDli tang
sinp cosz=2

12

where k refers to the kth segment, Dli is the length of each

segment, and g is the ank clearance angle. The geometry of a drill
element is shown is Fig. 6. At any instant, the depth of the
machined surface corresponding to each drill element is given by


f y  jp  kDy
Fy  jp  kDy
zmax;k0 A sin

n
2p
k 1; 2; . . . ; k

Fig. 3. End view of a drill showing its element on one of the cutting lips.

13

In Eq. (13), Dy is the rotational difference between each segment

(see Fig. 5), k is the total number of segments on each element,
and j is the minimum positive integer that satises the

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1073

Fig. 6. Geometry of one element on the drill cutting edge.

where

Dli W W cos o0 D=2cos o0  i  1=2Dwtan O

2k

Dw D cos o0  D0 cos o0
2M sin p

o0 tan1
and

o0 sin1

2W
D

W
W0

17

18


19


20

where M equals the number of elements in one cutting lip, D is the

diameter of the drill, and W0 equals half the length of the chisel
edge (see Fig. 3).
2.3. Strain rate-dependent shear strength model

Fig. 5. Geometry of drill elements and segments.

inequality:


f y  jp  kDy
A sin
n



Fy  jp  kDy
f y  j 1p  kDy
4A sin
2p
n

Fy  j 1p  kDy
2p

14

The theory behind Eq. (14) is same as the theory behind Eq. (5).
The plowing depth of the kth segment on a drill element can then
be calculated:

Tk  z0 max; k if Tk 4z0 max;k
15
Ddk
0
otherwise
The displaced volume per segment can then be calculated by
multiplying Ddk with Dli and the width of the element, Dw:

DVi

k
X
k1

Ddk Dli Dw

16

During metal cutting, the strain rate along the primary and
secondary shear zone reaches 103106 s1. These strain rates are
signicantly higher than the nominal strain rate (103101 s1)
used to determine generic material properties. Therefore, instead
of using the generic value, the JohnsonCook model will be used
to estimate the shear strength ti. The empirical constants used in
the JohnsonCook model for aluminum 6061-T6 were reported by
Guo [28]. These constants were ne-tuned slightly using some of
the experimental results, which will be presented in Section 3. In
the proposed model, ti is modeled by the following equations:



1
e_
21
ti 247:5 77:4e0:676 1 C ln
0:01
2
C 0:058  0:194hl  0:003V

22

cos gnd
sin fnd cosfnd  gnd

23

e_

V cos gnd
0:005 cosfnd  gnd

24

In Eqs. (21)(24), ti is the ultimate shear strength (MPa), e and e_

are the strain and strain rate, respectively, V is the instantaneous
cutting velocity (mm/s), and C is a unitless parameter. At a higher
vibration frequency, because of the increase in strain rate, the
shear strength of the material will be increased, resulting in a
higher thrust force.

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2.4. Thrust force model

The thrust force for VAD can be predicted by combining the
results of Sections 2.12.3 with a conventional mechanistic model.
The principle cutting forces along the cutting lips can be
calculated as discussed in [29]:
Fl;C

thl Dw coslnd  gnd

sin fnd cosfnd lnd  gnd

25

Fl;T

thl Dw sinlnd  gnd

sin fnd cosfnd lnd  gnd

26

In Eqs. (25) and (26), lnd is the dynamic friction angle, gnd is the
dynamic normal rake angle, and fnd is the dynamic shear angle.
Based on the methodology from [69], these angles can be
calculated using the following equations:

kr tan1 tanp coso

27

s

2


1
D cos o0  i 
ri
Dw W 2
2

b tan1



2ri tanb0
D

gf tan1

1

Zd tan

28

29

tanb sino
sinp  cosp sino tanb

z_ t
2pri n

krd tan1


30


31

sinkr
coskr cosZd tanls sinZd


32

lsd sin1 cosp sinZd sinp coso cosZd 

33

gfd gf Zd

34

gnd tan1
lnd
fnd

p
6

p
4

tangfd coslsd sinlsd

tankrd
sinkrd

gnd
2

gnd  lnd

35

36

37

In Eq. (29), b0 is the drill helix angle. Finally, the resultant thrust
force for each element can be calculated as

DPi Fl;T sin p cos Zd Fl;C sin Zd Fpt

38

The total thrust force can be found by adding all the elemental
thrust force components together.

3. Experimental apparatus

Fig. 7. Vibration-assisted workpiece holder.

because of the length of the tool, vibrating the tool axially also
potentially increases tool wobbling. In this study, it is more
desirable to produce axial vibrations on the workpiece. While the
relative displacement between the tool and the workpiece
remains unchanged, this approach provides a simple design
solution and reduces the potential of tool wobbling. A customdesigned piezoelectric actuated vibration-assisted workpiece
holder was designed and tested for this purpose. Fig. 7 shows
the schematic and a photograph of the workpiece holder. Details
of the mechanical and electrical design of this hardware are
presented in Chapter 5 of [30].
3.2. Experimental setup
Experiments have been conducted to verify the accuracy of the
developed model. Each test was performed on a Makino MC565XA horizontal CNC machine tool, with the vibration-assisted
workpiece xture attached onto a table dynamometer, which was
attached onto the machine table. The vibration amplitude was
chosen to be 0.002 mm, while the vibration frequency was varied
from 4 to 12 kHz in 2 kHz increments. Note that the static stiffness
of a typical 5-axis horizontal machine center is 30 kN/mm [31],
and the weight of the machine table is 58 kg. At the magnitude of
the induced vibration force, the resultant vibration amplitude of
the machine table at the lowest testing frequency (4 kHz) is
2.76  106 mm, and therefore is negligible. The drills used were
4.0 mm TiN-coated standard twist drills. The cutting conditions
chosen were 4000 rpm spindle speed and 0.06 mm/rev drill feed.
The workpieces were 3.18-mm-thick Al 6061-T6 plates
(25 mm  25 mm). Four drilling experiments were performed for
each cutting and vibration conditions. Thrust forces were
measured using Kistler Type 9255B table dynamometer with
sampling frequency equal to 10 times the corresponding vibration
frequency to avoid aliasing. The dynamometer has a natural
frequency of 2 kHz and stiffness of 3000 kN/mm (Kistler Instrumente AG [32]). At the magnitude of the induced vibration force,
the resultant vibration amplitude of the dynamometer at the
lowest testing frequency (4 kHz) is 1.22  105 mm, and again
is negligible. The mean values of the thrust forces for each
cutting and vibration condition were calculated for subsequent
comparison with the mean values of the corresponding model
predictions.

3.1. Vibration-assisted workpiece holder

4. VAD results and discussion
In order to perform experimental studies on VAD, it is
necessary to design an apparatus to produce the necessary axial
vibrations between the tool and the workpiece that is compatible
with conventional CNC machining center. In vibration-assisted
turning, vibrations are typically generated on the tool. Designing a
vibration-assisted tool holder for drilling is not trivial because of
the connection needed between the rotating spindle and the
external power source of the vibration actuator. Moreover,

The experimental mean thrust force results are compared with

the corresponding simulation results in Fig. 8. The solid data
points represent simulation results (based on Section 2), and
the hollow circular data points represent experimental data. The
maximum deviation between experimental results and the
simulations was 10%. When the vibration frequency equals
10 kHz, the thrust force is minimized, with a reduction of 16%.

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Fig. 8. Comparison between simulations and experimental results.

1075

due to the changes in strain rate in VAD with the variation of

dynamic uncut chip thickness.
Comparisons between experimental results and model predictions have shown the reliability of the developed model. The
mean values of the experimental thrust forces for all tested
conditions fall within 77% of the model predictions, and the
worst case error is 10%. The comparisons also demonstrated the
importance of modeling the plowing force and incorporating
strain rate-dependent shear strength for producing accurate
thrust force predictions. The proposed model predicted the
vibration frequency where thrust force is minimized, within the
frequency resolution employed in our experiments (2 kHz).
This work is important for industrial applications because
reducing thrust force can reduce tool wear, reduce burr size, and
increase the quality of the machined surfaces. Moreover, because
producing the vibration may be difcult, the proposed model can
also assist the user to determine if the effort required to achieve
the desired thrust force reduction is reasonable.

References

Fig. 9. Comparison between different simulation results.

Note that the thrust force reduction is dependent on the material

and cutting conditions.
Fig. 9 presents a comparison between the mean value of the
experimental thrust force measurements (averaged over each set
of four tests) and simulation results with both the plowing force
and strain rate-dependent shear strength models (simulation),
without the plowing force model (w/o Fpt), and without plowing
force and shear strength models (w/o Fpt and ti). Note that the
model w/o Fpt and ti represents the simulation results of the prior
models. The comparison shows that the mean thrust force
predictions fall within 20% of the experimental measurements
when using the prior models, and 7% using the proposed model.
The plot also shows that at higher vibration frequencies including
ti becomes more important. This is logical since increasing the
vibration frequency increases the strain rate. Both experimental
and simulation results consistently showed that a favorable
vibration frequency (10 kHz in this case) that minimize thrust
force exists. Note that we have obtained similar results for other
drills and cutting conditions.

5. Conclusions
A novel analytical thrust force model for VAD has been
proposed. Instead of modeling only the variation of dynamic
uncut chip thickness, the proposed model incorporates the
presence of plowing forces and the variation of shear strength

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