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Predicting thrust force for drilling fiber reinforced polymers using twist drills

Fiber reinforced polymers (FRPs) are used in a range of industries because of their excellent mechanical properties and light weight. Drilling with twist drills is the most frequent machining operation to connect FRP parts with other structural components and the level of drilling thrust force is a key factor which influences the final quality of hole-making. Hence This article presents a mechanistic model to predict the thrust force during drilling FRPs under different drilling parameters. This model is established based on the geometry of the drill bit and orthogonal FRP composite cutting, and the thrust forces created by both the chisel edge and main cutting lips can be calculated separately. The results were validated by the experimental data and the differences were all within 5% intervals, showing that this model can be used for drilling thrust force prediction satisfactorily.