A comprehensive 3D finite element simulation study has been conducted to investigate the tool temperature distribution along cutting edge and chip formation during drilling of Ti6Al4V alloy by using commercial finite element software Abaqus/Explicit. The Johnson-Cook material constitutive model and material failure criterion were implemented across the formulations to achieve the tool temperature and chip formation in the drilling process. The effect of different mesh sizes on simulation results was also analyzed. To assess and verify the accuracy of the simulation model, the corresponding experiment studies were carried out by measuring the thrust force, tool temperature, and chip morphology. Compared results show that the predicted thrust force, temperature distribution, and chip morphology are in good agreement with those tested from experiments. According to the combination of both simulations and experiments, it can be not only found the whole varying pattern of the thrust force but also reveal that the temperature decreases from drill center to outer corner along the primary cutting edge. In addition, it can provide a more detailed and profound knowledge about chip formation. All these are assumed to be recommendations for the optimization of tool geometry and drilling processing.

Drilling is regarded as the most complex manufacturing process compared with other conventional machining processes. During the drilling process, most of the energy consumed in metal cutting is converted to heat and increases temperature considerably. The resulting thermal phenomena are important since they influence the mode of deformation, the final metallurgical state of the machined surface, and the rate of tool wear. Hence, understanding the temperature characteristics in the drilling process is crucial for enhancing the drill performance and process efficiency. Extensive efforts have been conducted to measure and control the drilling tool temperature successively. However, very few studies have been conducted from a comprehensive perspective to review all the efforts. To address this gap in the literature, a rigorous review concerning the state-of-the-art results and advances in drilling tool temperature is presented in this paper by referring to the wide comparisons among literature analyses. The multiple aspects of drilling tool temperature are precisely detailed and discussed in terms of theoretical analysis and thermal modeling, methods for temperature measuring, the effect of cutting parameters, tool geometries and hole-making methods on temperature and temperature controlling by different cooling methods. In conclusion, several possible future research directions are discussed to offer potential insights for the drilling community and future researchers.