Mechanics of Drilling Process: Analytical, Experimental, and Statistical Perspective on Tool Geometry Effect

Abstract

Drilling is one of the most widely used machining processes in manufacturing industries for producing precise and functional holes in metallic and composite materials. This review article presents a comprehensive analysis of drilling mechanics from analytical, experimental, and statistical perspectives with particular emphasis on the influence of tool geometry on drilling performance. The study examines the effects of point angle, helix angle, clearance angle, chisel edge, and web thickness on chip formation, cutting forces, torque generation, burr formation, surface quality, and tool wear. Analytical models, experimental investigations, and statistical optimization techniques such as Design of Experiments (DOE), Response Surface Methodology (RSM), ANOVA, regression modelling, Grey Relational Analysis, and TOPSIS are critically reviewed. The literature indicates that optimized tool geometry significantly improves hole quality, reduces burr formation, minimizes tool wear, and enhances machining productivity. The review also identifies important research gaps related to generalized predictive models, integrated optimization frameworks, and industrial implementation. The findings provide a valuable foundation for future research on intelligent, sustainable, and high-performance drilling systems.

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