Current research studies devoted to cutting forces in drilling are oriented toward predictive model development, however, in the case of mechanistic models, the material effect on the drilling process itself is mostly not considered. This research study aims to experimentally analyze how the machined material affects the feed force (Ff) during drilling, alongside developing predictive mathematical–statistical models to understand the main effects and interactions of the considered technological and tool factors on Ff. By conducting experiments involving six factors (feed, cutting speed, drill diameter, point angle, lip relief angle, and helix angle) at five levels, the drilling process of stainless steel AISI1045 and case-hardened steel 16MnCr5 is executed to validate the numerical accuracy of the established prediction models (AdjR = 99.600% for C45 and AdjR = 97.912% for 16MnCr5). The statistical evaluation (ANOVA, RSM, and Lack of Fit) of the data proves that the drilled material affects the F_f value at the level of 17.600% (p < 0.000). The effect of feed represents 44.867% in C45 and 34.087% in 16MnCr5; the cutting speed is significant when machining C45 steel only (9.109%). When machining 16MnCr5 compared to C45 steel, the influence of the point angle (lip relief angle) is lower by 49.198% (by 22.509%). The effect of the helix angle is 163.060% higher when machining 16MnCr5.

This article deals with drilling, the most common and simultaneously most important traditional machining operation, and which is significantly influenced by the properties of the machined material itself. To fully understand this process, both from a theoretical and practical perspective, it is essential to examine the influence of technological and tool-related factors on its various parameters. Based on the evaluation of experimentally obtained data using advanced statistical methods and machine learning decision trees, we present a detailed analysis of the effects of technological factors (f_n, v_c) and tool-related factors (D, ε_r, α₀, ω_r) on variations in torque (M_c) during drilling of two types of engineering steels: carbon steel (C45) and case-hardening steel (16MnCr5). The experimental verification was conducted using CTS20D cemented carbide tools coated with a Triple Cr SHM layer. The analysis revealed a significant influence of the material on torque variation, accounting for a share of 1.430%. The experimental verification confirmed the theoretical assumption that the nominal tool diameter (D) has a key effect (53.552%) on torque variation. The revolution feed (f_n) contributes 36.263%, while the tool’s point angle (ε_r) and helix angle (ω_r) influence torque by 1.189% and 0.310%, respectively. No significant effect of cutting speed (v_c) on torque variation was observed. However, subsequent machine learning analysis revealed the complexity of interdependencies between the input factors and the resulting torque.

Additive and coating technologies, such as high-velocity oxy-fuel (HVOF) thermal spraying and direct metal laser sintering (DMLS), often require extensive post-processing to meet dimensional and surface quality requirements, which remains challenging for nickel-based superalloys such as Inconel 718. This study presents the design and topology optimisation of a cutting tool with a linear cutting edge, capable of operating in turn-milling or turning modes, offering a viable alternative to conventional grinding. A non-optimised tool served as a baseline for comparison with a topology-optimised variant improving cutting-force distribution and stiffness-to-mass ratio. Finite element analyses and experimental turn-milling trials were performed on DMLS and HVOF Inconel 718 using carbide and CBN inserts. The optimised tool achieved significantly reduced roughness values: for DMLS, Ra decreased from 0.514 ± 0.069 µm to 0.351 ± 0.047 µm, and for HVOF from 0.606 ± 0.069 µm to 0.407 ± 0.069 µm. Rz was similarly improved, decreasing from 4.234 ± 0.343 µm to 3.340 ± 0.439 µm (DMLS) and from 5.349 ± 0.552 µm to 4.521 ± 0.650 µm (HVOF). The lowest measured Ra, 0.146 ± 0.030 µm, was obtained using CBN inserts at the highest tested cutting speed. All improvements were statistically significant (p < 0.005). No measurable tool wear was observed due to the small engagement and the use of a fresh cutting edge for each pass. The resulting surface quality was comparable to grinding and clearly superior to conventional turning. These findings demonstrate that combining topology optimisation with a linear-edge tool provides a practical and efficient finishing approach for additively manufactured and thermally sprayed Inconel 718 components.

This study investigates the influence of tool geometry and cutting parameters on thrust forces and process stability during the drilling of 90MnCrV8, a hard and wear-resistant tool steel. The objective was to identify the dominant and interactive effects of feed per revolution (f_rev), nominal tool diameter (D), cutting speed (v_c), and geometry angles (ε_r, α_o, ω_r) on the thrust force (F_f). Experimental data were evaluated using analysis of variance (ANOVA) to determine statistical significance and effect size (η²), supported by theoretical models by Kienzle, Merchant, Oxley and Zorev to explain observed physical trends. Feed per revolution had the most decisive influence on thrust force (η² = 0.690; p < 0.001), followed by tool diameter (D; η² = 0.188). Geometric parameters showed secondary yet significant effects, mainly on stress distribution and chip evacuation. The interaction between D and f_rev produced a multiplicative force increase, while the combination of f_rev and helix angle (ω_r) reduced friction at higher feeds. Cutting speed had a minor effect (η² = 0.007), suggesting limited thermal softening. The findings confirm that drilling hard steels is primarily governed by the energy of plastic deformation.

The titanium alloy Ti-6Al-4V is widely used in the aerospace, medical, and automotive industries; however, its machining remains challenging due to its low thermal conductivity and high chemical reactivity. This study investigates the influence of the tool clearance angle on tool wear during the turning of Ti-6Al-4V under wet cutting conditions. A Design of Experiments (DoE) approach was employed, varying the clearance angle, cutting speed, and feed rate to determine their effects on tool wear. Tool wear was analysed using 3D topography measurements. Regression analysis was used to evaluate the experimental data with the main objective of quantifying the impact of the individual factors and their interactions, resulting in the development of a predictive statistical model. The model’s accuracy was assessed using the coefficient of determination (R²) and the adjusted coefficient of determination (R²adj). The results demonstrate that the clearance angle has a significant impact on crater wear formation and overall tool life. An optimised moderate clearance angle reduces tool degradation, enhances tool life, and improves the surface integrity of the machined component.