Pre-hole diameter optimization in high speed drilling considering machining cost

In this paper, a new methodology of tool diameter optimization in high-speed peck drilling cycle G83 is investigated in order to predict the pre-drill diameters and cutting speed which lead to the minimum cutting cost. In this aim, a pre-drill diameter modeling is proposed. The cycle time is calculated based on a feed rate modeling which depends on the kinematic performance of the machine. To reach higher precision of the predicted results, an optimization algorithm is developed taking into consideration the technological and machine constraints (machine power, spindle speed, and feed rate). An experimental study is carried out to validate the feed rate modeling and to calculate the value of the specific cutting force of studied material. To demonstrate the procedure, an illustrative example of AISI 4140 workpiece material is discussed in detail. The obtained results show that the economical process of drilling in peck drilling cycle G83 is obtained with the minimum number of pre-drill diameter.