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In high-throughput drilling of the compacted graphite iron (CGI), which is a high-strength, difficult-to-machine cast iron for lightweighting applications, the drill temperature and wear are critical for the drilling outcome. As the drill main cutting edges are subject to the high cutting forces, the elevated temperature along the cutting edges greatly impacts the drill life. However, there is a lack of research to predict the spatial and temporal cutting edge temperature distributions as well as its change along the tool wear progression. A tool-foil thermocouple method is adopted in this study to directly measure the drill main cutting edge temperature in high-throughput CGI drilling. Results are cross validated based on a combination of finite element modelling and experimental measurement of the cutting edge temperature from embedded thermocouples 1.0 mm away from the cutting edge. Drilling experiments using the tool-foil measurements show that, along the main cutting edge, the drill center has a higher temperature than that of the outer corner. With increasing drilling depth, the temperature difference along the main cutting edge gradually decreases. Moreover, adhesion-dominated tool wear has changed the cutting edge temperature, leading to higher temperature rise in the middle and outer corner regions along the cutting edge than at the drill center. Similar trend occurs in the drill flank wear, thrust force, torque, and average cutting edge temperature as the number of holes made by the same drill increases. © 2025 The Society of Manufacturing Engineers
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Journal of Manufacturing Processes
ISSN: 1526-6125
Year: 2025
Volume: 150
Page: 74-87
6 . 1 0 0
JCR@2023
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