A Cutting Force and Hole Geometry Study for Precision Deep-Hole Microdrilling of Magnesium

Size effects, high thrust forces, limited heat dissipation, and tool deterioration are just some of the challenges that deep microdrilling poses, underscoring the importance of effective process control to ensure quality. In this paper, an investigation performed on a microdrilling process on pure magnesium using a 0.138 mm diameter microdrill to achieve an aspect ratio equal to 36 is proposed. The effect of the variation of the cutting parameters feed per tooth (Formula presented.) and cutting speed (Formula presented.) was studied on thrust force, supporting hole quality evaluation in terms of burr height, entrance, and inner diameters. The results showed that (Formula presented.) significantly influences the hole quality. In fact, as (Formula presented.) increases, the burr height decreases and the inner diameter approaches the nominal diameter. However, optimizing the hole geometry with high feed per tooth values increases the thrust forces, compromising tool life. In fact, a significant dependence of the thrust force on both cutting parameters was found. In this scenario, increasing (Formula presented.) can mitigate the high thrust forces by inducing material softening. The study results improve precision manufacturing by refining parameters, ensuring the quality and reliability of magnesium-based microcomponents.