IOP Conference Series: Materials

Science and Engineering

PAPER • OPEN ACCESS You may also like

- Fluting Modes in Transversely Nonuniform
A Novel Method of Twist Drill Fluting Fulfilling Solar Flux Tubes
Roberto Soler
Required Web Thickness and Rake Angle - Study on the atomic removal behavior and
damage formation mechanism of nano
cutting copper–nickel alloy with diamond
To cite this article: Li Zhuyu et al 2018 IOP Conf. Ser.: Mater. Sci. Eng. 423 012128 tool
Yan He, Zikai Gao, Meiling Tang et al.

- THE EFFECT OF A TWISTED

MAGNETIC FIELD ON THE PERIOD
RATIO P1/P2 OF NONAXISYMMETRIC
View the article online for updates and enhancements. MAGNETOHYDRODYNAMIC WAVES
K. Karami and K. Bahari

This content was downloaded from IP address [Link] on 28/02/2024 at 08:12

ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

A Novel Method of Twist Drill Fluting Fulfilling Required

Web Thickness and Rake Angle

Li Zhuyu, Wang Hongyang, Hu Jianzhong, Zhang Wei

School of Mechanical Engineering and Automation, Dalian Polytechnic University,
Dalian 116034, China
Corresponding author’s e-mail address: li_zy@[Link] (Li Zhuyu)

Abstract. As substitute of the meshing theory based fluting method, other analytical,
machining movement simulation or empirical method are developed in last decades. Currently,
a kind of flute prevails. It is ground by using 1V1/1A1 standard grinding wheel and should
fulfil requirements of designated web thickness and radial rake angle. This paper presents a
novel method by straightforwardly determining install position of the grinding wheel. Based on
the relative movement with variables’ parameterization, equations to keep web thickness are
firstly derived. Then, a family of flute cross-sectional curves is computed automatically with
respect to grinding process parameters and wheel geometry. The calculation process is
characterized by concise in principle and easy to use. Its validity is verified by good agreement
between the results computed and manufactured example.

1. Introduction
Twist drill flute influences chip evacuation and cutting edge configuration. It also determines the flute
parameters, i.e. the web thickness and radial rake angle. All these factors are essential to drill
performance [1-2]. Originally, the flute profile was shaped by meshing method as in gear
manufacturing. This process seems to be laborious [3], due to the complex surface of formed grinding
wheel with excessive rigid in precision. It is not easily adapting to ever demanding of flute
performance improvement [4]. As a large batch production tool, the grinding wheel is liable to be
worn. The meshing theory based reconditioning is difficult and expensive, especially to grind the
integrated carbide twist drills with diamond grinding wheels. Different kinds of practical and
simplified drill fluting methods were developed [5-7].
Currently, a kind of twist drill flute prevails. It is ground by using 1V1/1A1 standard wheel and
providing with specific web thickness and radial rake angle [8]. The former is dominating to drill
stiffness and the later is influential to chip evacuation. There were a few papers in the literature
dedicated to this topic. Some work solved this problem based on empirical design [9]. The wheel
position should be assumed before matching a formed wheel profile by meshing method [10]. Graphic
analysis and simulation in 2D/3D, using Boolean operations, are not easy to ensure the accuracy of the
designed flute profiles [11-13]. Another paper handled it by numerical exploration with lengthy
iterations [14]. Difficulty of the problem lies in fulfilling both web thickness and rake angle
requirements simultaneously, since they are usually tangled up [15]. This paper presents a novel
method to find a more effective solution.
It is evidenced in direct method of twist drill flute grounding [5], the profile is determined by
installation angle, centre and eccentric distances between the wheel and drill blank axes. This
peculiarity provides a break through to separate the perplexity mentioned above. Firstly, the web

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

thickness requirement can be achieved by setting a unique centre distance directly. Finally, the rake
angle requirement is fulfilled by determining the eccentric distance. Using these mentioned two
requirements as constrains, the problem can be simplified and solved by a linear search. The valid
flute profiles with the same required web thickness and rake angle are calculated and illustrated.
Contents of the next sections are arranged as follows: strategy to fulfil the web thickness
requirement alone by determining the centre distance between the wheel and drill blank is explained in
section 2; mathematic modelling of the system and variables’ parameterization to calculate the flute
profile and to determine the radial rake angle are deduced in section 3; one-dimensional exploration to
determine the eccentric distance is described in section 4; precision comparison of example computed
and that manufactured are illustrated in section 5; the influence of grinding process parameters and
wheel profile parameters on flute geometry is discussed in section 6; concluding remarks are
summarized in section 7.

2. Determining centre distance between drill blank and wheel fulfilling the required web
thickness
Coordinate systems of the drill and grinding wheel and some nomenclatures are introduced as shown
in Fig.1. The global coordinate system is {O: X, Y, Z}. It is right-handed and originated at the end
centre of the drill. The upward axis Z coincides with the drill axis. {O1: X1, Y1, Z1} is the moving system
attached to the grinding wheel. Initially, axis X1 coincides with axis X and axis Z1 is skew to axis Z with
distance A, called as centre distance. At initial position, distance of the grinding wheel rear face to
origin O1 is T1 called as eccentric distance. The grinding wheel rear face is parallel to the X1O1Y1 plane
and its axis Z1 is inclining to Z axis with angle β named as installation angle. A, T1 and β determine the
wheel orientation fixed in the machining movement, called as grinding process parameters. The helical
parameter P (P = L/2π, L is the lead) is also invariable.
In Fig.2, rw is the radius of the inscribed circle in the flute cross-section. It is the half web thickness.
Radial rake angle γ is an angle at the radius end. It is the intersecting angle of the radius and tangent of
the flute cross-sectional profile at this point. Flute width δ is the angle formed by line PsO and line
PeO at the point O. Ps is the start point and Pe is the terminal point of the flute profile. Flute width
influences the chip evacuation capacity and the rigid of drill body.

Fig.1 Coordinate systems Fig.2 Web, radial rake angle and Fig.3 1V1 grinding wheel
flute width

1V1/1A1 grinding wheel are most widely used in the process of twist drill fluting. 1A1 wheel can
be regarded as a specific 1V1 wheel with the inclined angle λ=90°. In this section, a general
mathematical model using 1V1 wheel is provided. In Fig.3, wheel profile is determined by four
parameters: wheel radius r, wheel width W, fillet radius ρ and inclined angle λ. The wheel’s 3D figure
can be dispersed as slices with different radius. The sheet with the maximum radius is denoted as Q. In
Fig.4, The auxiliary coordinate system {O2: X2, Y2, Z2} is located on O2 the centre of Q. The axis X2
coincides with axis X and axis Y2, Z2 is parallel to axis Y, Z, respectively. In the conformal projection,

2
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

an arbitrary sheet on the wheel is an ellipse, projecting on X2O2Y2 plane. The outer profile of all these
meshing ellipses, named as curve S1 (with red colour in Fig.4), is the whole wheel’s projection. The
coordinates of an arbitrary projection point on the X2O2Y2 plane is expressed as parametric (elliptical)
equation,
 x 2  ( r     sin  ) cos 
 y  ( r     sin  ) cos  sin    cos  sin  (1)
 2
where φ is the circumferential angle of the sheet on the fillet radius. It determines the position of a
sheet on the Y1O1Z1 plane. In the X1O1Y1 projection, θ is the central angle of the point on this round
sheet (in Fig.3). The outer profile can be calculated by the envelope equation of planar curves[16],
x2/  y2/  y2/  x2/  0 (2)
The partial derivatives are derived by Eq.(1). Then, Eq. (2) can be simplified below,
sin  1/(tan  tan ) (3)
For a given φ, there is a specific angle θ calculated by Eq. (3), called as envelope angle, corresponding
to a sheet on the wheel. All these envelope points can be calculated by substitution of the envelope
angle θ into Eq. (1). They form the outer profile of wheel projection, named as curve S1. So Eq.(1) can
express S1 when θ satisfies Eq.(3). As the drill blank moves helically, the S1 configuration remains
unchanged and revolves around point O with the installation angle.
A simplest condition is considered as shown in Fig.4. The wheel’s sheet Q with the maximum
radius is located at the drill blank upright direction. To keep half web thickness rw, the centre distance
A should be given by:
A  r  rw (4)

f(φ)
4.0

3.0

2.0

1.0

π/2−β π/2

Fig.4 Grinding wheel and drill blank position Fig.5 Merit function f(φ)
As detailed in the paper [5], the direct method of drill flute modelling is based on considering
relative motion of the drill blank, while the wheel is assumed to be standstill, the flute profile is
determined by varying the centre distance A and eccentric distance T1. Considering relative motion,
the drill centre should move along the curve S2 (dashed curve with blue colour in Fig.4) projected on
the X2O2Y2 plane. In order to keep the required half web thickness, rear surface of the grinding wheel

3
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

should move along the curve S2 equidistant to S1. This conclusion reveals a breakthrough to solve the
difficulty. After ensuring the web thickness, the way is paved to pursue the radial rake angle as
another objective.

3. Modelling the relative movement by using parameterized variables

To achieve the objectives mentioned above, the first step is to model the relative motion of the
grinding wheel. The wheel centre is assumed to be moving around the fixed drill blank along curve S2
as an equidistant curve of S1 (Fig. 4). It can be solved conveniently by using differential geometry [16].
The variable’s parameterization is effective in this procedure. All the expressions and derivations
shown below are in accordance with this curriculum.
Considering relative motion, the wheel is assumed to be standstill. Accordingly, the centre distance
A and eccentric distance T can be assumed. Coordinates of the drill blank axis are designated by xm and
ym denoting relative position of the wheel and drill (Fig.4), expressed in Eq. (5),
 xm   A
 (5)
 y m  T1 sin 
A curve S2 equidistant to the ellipse S1 is drawn on the XOY plane (Fig.4). The distance is equal to
the required half web thickness rw. If the drill axis is adjusted to be located on the curve S2 all the
while, the half web thickness requirement for the drill after fluting is fulfilled. Coordinates xm and ym
of the drill axis should fulfil the equation of the equidistant curve S2. Equation of the curve S1 with
parameter φ (expressed in radian) should be determined at first as shown in Eq.(1), noted in terms of
vectors.
α ( ) （ x , y ,0)  ((r    sin ) cos , (r    sin ) cos  sin   cos sin  ,0) (6)
In order to derive the equidistance curve S2, normal vector n on an arbitrary point of S1 is
determined as shown in Eq.(7)..
(α 'α ' )α ' '(α'α ' ' )α '
n (7)
α ' α 'α ' '
where α' and α'' is the first-order and second-order derivative of α(φ). According to the offset
curve theory expounded in [17], parametric equation of the curve S2 is given by Eq.(8).
αˆ ( )  α ( )  rw n (8)
The given value xm and ym should fulfil Eq.(5). It is expressed in Cartesian coordinates, as shown in
Eq. (9).
 xm   x  rw n x
y    r n (9)
 m y w y
Substituting Eq.(5) into (9), expressions of the centre distance and eccentric distance are given by
Eq. (10). That is the parameterized centre distance and eccentric distance.
 A  ( x  rwn x )
T  (  r n ) / sin  (10)
 1 y w y
where the coordinates of the normal vector n can be calculated by substituting Eq.(6) into (7).
n   ' /  ' 2  ' 2
 x y x y (11)

n y   ' x /  'x  ' y
2 2

 ' x  cos cos   ( r    sin )sin /(sin  tan  )

2

 (12)
 ' y  cos cos  sin   (r    sin )coscos /(sin  tan  )  sin sin 
2

For an arbitrary parameter φ, centre distance A and eccentric distance equation T1 are determined
by Eq. (10). As shown in section 2, A is defined in Eq. (4) as (r+rw). It has been witnessed as the very

4
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

solution of the first objective of the paper fulfilling the requirement of web thickness. The second
objective is to fulfil the requirement of radial rake angle γ0. Its solution is the contents of the section to
follow.

4. Fulfilling the required radial rake angle γ0

There are two steps to fulfil the requirement of radial rake angle γ0: firstly, the radial rake angle
calculation procedure is introduced and furthermore its exploration region is determined; secondly,
one-dimensional exploration procedure by using golden section search [18] is synopsized; finally,
optimal value is the required angle γ0 with the corresponding eccentric distance T1.
The radial rake angle is determined by numerical differentiation to calculate the curve tangent at
the radius end by using B-Spline or software in MATLAB.
As preparatory work to explore the rake angle approaching the required value γ0, the range of
exploration is determined by a large number of examples calculating the radial rake angle with
different parameters φ. It manifests that the drill centre is located at lower right position of the curve S2
according to the grinder configuration. It concludes that the parameter φ should be within the range
φ∈[π/2−β, π/2], corresponding to the point B and point A with inclined installation angle (Fig.4). As
shown in Fig.5, the merit function f(φ) is expressed in square of (γ(φ)−γ0) shown in Eq. (13).
min f(φ)= (γ(φ)−γ0)2 , φ∈[π/2−β, π/2] (13)
It is modelled and can be solved by one-dimensional numerical optimization with the well known
method of golden section search.
cross-sectional curve
cross-sectional curve

γ=4.89˚ γ=15.16˚
rw=1.111
rw=1.108

wheel
wheel

(a) type I (b) type II (a) (b)

Fig.6 Machining locus Fig.7 Samples of cross-sectional profile

Table 1
Dimensions of the drill and grinding wheel
Diameter of the drill: d(mm) 7.988

Helical parameter: P(mm) 6.918

Wheel radius: r (mm) 123.290/2

Wheel width: W(mm) 12.136

Wheel fillet radius: ρ（mm） 0.13

Wheel inclined angle: λ（°） 70

5
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

Table 2
Iterative data
No. φ f(φ)
1 0.399940 28.6162
2 0.647204 19.1794
3 0.799988 10.0857
10 0.926693 0.0347473
15 0.926327 0.00272582
19 0.926354 1.18785e-5
21 0.926355 4.74384e-5

Table 3 Comparison of the calculated and measured data

Designed Measured Errors

Sample a Half web thickness: rw（mm） 1.100 1.108 0.73%

Fig.7(a) 5.00 4.89 2.20%
Radial rake Angle: γ(deg）

Sample b Half web thickness: rw（mm） 1.100 1.111 1.00%

Fig.7(b) Radial rake Angle: γ(deg） 15.00 15.16 1.10%

5. Example
The centre distance A and eccentric distance T1 for an arbitrary parameter φ are determined according
to Eq. (10). The corresponding flute profile is determined by using direct movement simulation
method [5]. The machining locus is shown in Fig.6 and the manufactured flute cross-sectional profile
is shown in Fig.7. There are two types of flute profile corresponding to variety curves mentioned
above:

(a) (b)

6
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

(c) (d)
Fig.8 Influence of wheel installation angle β on flute profile

γ=0° γ=5° γ=10° γ=15° rw =0.55 rw =1.1 rw =2.2

Fig.9 Comparison of width angle of flute Fig.10 Comparison of width angle of flute with
with the same core the same rake angle

(a) (b)

7
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

(c) (d)
Fig.11 Influence of wheel geometry on flute profile
Type I. The whole cross-sectional curve is concave in Fig.6(a). The flute profile is generated
only by the wheel’s fillet radius.
Type II. This is a combination of both enveloped and non-enveloped curves in Fig.6(b). The front
section is the same as type I. The rear section is generated by the wheel’s rear face. It shows the front
section is concave and the rear section is convex.
Dimensions of the drill and grinding wheel are listed in table 1. Iterative data are listed in table 2.
Comparison of the calculated and measured data is listed in table 3. The results can be summarized as
follows: The convergence precision achieves ε =10-4, after 21 times’ iteration. Errors of the web
thickness and radial rake angle are no more than 2.2%, respectively.

6. Discussion

6.1 Evaluation of installation angle

According to Fig. 1, only three parameters (A, T1 and β) determine the wheel position. A 1V1 grinding
wheel is used in this example, with the parameters shown in Tab.1.
The cross-sectional profiles of flute under different requirements of γ=0°,5°,15° and rw=1.1mm,
2.2mm are generated. As shown in Fig. 7(a), with the increase of β from 40° to 60°, the rear section of
flute moves upward and the flute width δ decreases while the front section remain unchanged. Overcut
appears in the rear section when the value of β less than 50° under the required γ=15° in Fig. 7(b). It
causes the flute width δ drops quickly. In Fig. 7(a) (γ=0°) and Fig.7(c) (γ=5°), the shape of flute
profiles keeps concave, belonging to type I flute curve. But in Fig.7(b) (γ=15°), flute profiles are
mostly type II and the concave section only appears in a limited range β∈[50°, 60°]. When the
required web thickness increases, the flute becomes narrower. In comparison the profiles in Fig.7(d)
(rw= 2.2mm) with Fig.7(c) (rw= 1.1mm), the curvature and the flute width of flute profile is smaller.

8
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

6.2 Evaluation of wheel geometry

As shown in Fig. 3, the wheel geometry is mainly described by four variable parameters: wheel radius
r, wheel width W, fillet radius ρ and inclined angle λ. When wheel radius r increases from ϕ40mm to
ϕ130mm, fulfilling the requirements rw=1.1 and γ=15°, the flute width δ only increase 5% in Fig. 10(a).
It indicates that the wheel radius r has a little effect to flute width δ. Some numerical examples at other
different conditions show the similar results. It is convenient and applicable in practical operations.
According to this conclusion, different wheel radius can be selected to grinding the same required flute
profile. Furthermore, if the wheel outer surface has a slightly worn-out, it will cause the order of tens
of micrometers modification and amendment of wheel radius. It hardly has much influence to the
ground flute profiles.
As shown in Fig. 10(b), along with the increasing of fillet radius ρ, flute width δ increases slowly.
In practice, the fillet radius ρ is normally selected no more than 5mm, considering the curvature of
flute profiles restriction. So the fillet radius ρ has a slight effect on the flute too. Using the above
calculation process, the wheel’s position will be self-adaptive to the different required web thickness
and rake angle.
Fig. 10(c) and (d) show that width W and inclined angle λ just influences the flute width. The flute
width increases with W increasing within the range W∈[1 mm, 5 mm] and all the generated flute
curves are type II. When wheel width W is larger than 5mm, overcut occurs on the rear section by the
wheel rear face. In this time, the illustrated flute curves coincide and the flute geometry will not be
affected any more. Similarly, when the inclined angle λ is larger than 70°, overcut occurs on the rear
section too. This is a guidance to select wheel. If the required flute profile is type II, a large value of
wheel width or inclined angle should be selected; in the contrast, a small width or inclined angle wheel
is advantageous to form type I flute curve. Further information using different wheel with complex
shapes will be explored by the proposed modelling method. It is the basic work for developing a flute
curve pattern system with distinguish and recognition to orient the experimental exploration for drill
performance improvement.

7. Concluding remarks
A novel method of twist drill fluting by using 1V1/1A1 wheel fulfilling required web thickness and
radial rake angle is studied. The most effective conception in solving the difficulty is separating these
requirements into independent parts. Considering the machining process as relative motion of the drill
blank with respect to the grinding wheel, centre of the drill is moving along a curve. It provides
constraint to the wheel installation position fulfilling the web thickness requirement. The remaining
requirement of rake angle is determined by one-dimensional exploration. It is worthy of mentioning
that involved derivation and computation are simplified by using direct method for twist flute
modelling. In the context, differential geometry is very helpful in clarifying the basic idea explanation
and providing an accurate and easy method of computation.
Validity of the proposed method is demonstrated by accurate agreement of the computed example
with that manufactured. The above mentioned system has been embedded in the operational software
of our machine tool. The novel fluting method is fulfilled effectively.

Acknowledgements
The authors would like to acknowledge the financial support by the General Project of Liaoning
Province Educational Committee (L2015046).

References
[1] Astakhov V P 2010 Geometry of Single-point Turning Tools and Drills (New York: Springer)
p205-330
[2] Bogale T M, Shiou F J, Tang G R 2015 Arab J Sci Eng.40 1497-1515
[3] D. Kang, E. Armarego 2007 Mach. Sci. Technol. 7 221–248
[4] Abele E, Fujara M 2010 CIRP Ann-Manuf Technol.59 145–150

9
ICAMMT 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 423 (2018) 012128 doi:10.1088/1757-899X/423/1/012128
1234567890‘’“”

[5] Zhang W, Wang X, He F 2006 Int J Mach Tool Manuf. 46 667-672

[6] Rababah M M, Chen Z C. 2013 J Manuf Sci E-T ASME.135 011011-1
[7] Guochao Li 2017 Int J Adv Manuf Technol. 90 775-784
[8] Ren L, Wang S, Yi L 2015 Precis. Eng. 43 387-394
[9] V H Nguyen, S L Ko 2013 CIRP Ann-Manuf Technol.62 323–326.
[10] C J Chiang, Z H Fong , J T Tseng 2009 J Mech Mach Theory 44 685–696
[11] Kim J H, Park J W, Ko T J 2008 Computer-Aided Design. 40 324-333
[12] L Ren, S Wang, L Yi, S Sun 2016, Precis. Eng. 43 387–394
[13] Li G, Sun J, Li J. 2014 Int J Adv Manuf Tech. 75 959-966
[14] Karpuschewski B, Jandecka K, Mourek D 2011CIRP Ann-Manuf Technol. 60 347-350
[15] Li G, Zhou H, Jing X 2017 Int J Mach Tool Manuf. 122 149-160
[16] Nutbourne A W, Martin R R1988 Differential Geometry Applied to Curve and Surface Design
(Chichest: E Horwood) p17-31
[17] Patrikalakisp N M, Maekawa T 2002 Shape interrogation for computer aided design and
manufacturing (New York: Springer) p316-318
[18] Luenberger B D G 2008 Linear and Nonlinear Programming (London: Springer) p216-219

10