Experimental and FE analysis of thrust force, burr formation, and tool wear in drilling aluminized steel

This study presents a combined experimental and numerical investigation of the effects of drilling parameters on thrust force, burr formation, surface integrity, and tool wear in aluminized steel. Drilling tests were performed under dry conditions at spindle speeds of 3000 and 6000 rpm and feed rates ranging from 50 to 200 mm/min, and a three-dimensional finite element model was developed to predict thrust force behavior. Both experimental and numerical results revealed that feed rate is the dominant factor, with thrust force increasing nearly linearly as feed rate rises, leading to severe plastic deformation and cap-type burr formation. In contrast, lower spindle speed (3000 rpm) provides better surface finish and more stable tool wear evolution, resulting in longer tool life. Although higher spindle speed (6000 rpm) reduces thrust force due to thermal softening, it accelerates tool wear through increased temperature and material adhesion. Overall, the findings demonstrate that the combination of low feed rate and low spindle speed yields optimal performance by improving surface integrity, reducing burr formation, and extending tool life. This optimization contributes to enhanced process efficiency and reduced need for secondary operations.