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Accuracy Analysis of Holes Drilled in Ductile Cast Iron with an HSS Helical Drill Bit.

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Title: Accuracy Analysis of Holes Drilled in Ductile Cast Iron with an HSS Helical Drill Bit.
Authors: Sójka, Radosław1 (AUTHOR) rsojka@tu.kielce.pl, Ziarkowski, Piotr1 (AUTHOR), Klamczyński, Kamil1 (AUTHOR), Kowalska, Natalia1 (AUTHOR), Blasiak, Slawomir1 (AUTHOR), Nowakowski, Lukasz1 (AUTHOR), Skrzyniarz, Michal1 (AUTHOR)
Source: Materials (1996-1944). Jun2026, Vol. 19 Issue 12, p2606. 19p.
Subjects: Machining, Bits (Drilling & boring), Nodular iron, Surface roughness
Abstract: Controlling macro-geometrical errors in the dry drilling of ductile cast iron remains a critical challenge for sustainable and cost-efficient automotive component manufacturing. This paper investigates the influence of cutting speed (vc) and feed per revolution (fn) on the dimensional and shape accuracy of holes drilled in EN-GJS-500-7 ductile cast iron using an HSS DIN 338 helical drill (Ø 11.8 mm, Ceratizit) on an AVIA VMC800 CNC milling centre. A one-factor-at-a-time (OFAT) experimental design was applied: the feed effect was evaluated at vc = 10 m/min with fn ∈ {0.10, 0.15, 0.20} mm/rev, while the speed effect was evaluated at fn = 0.20 mm/rev with vc ∈ {10, 25, 30} m/min. Cutting forces, torques, and vibration accelerations were recorded using an HBM MSC 10 transducer and a PCB 356A01 tri-axial accelerometer. Hole geometry was assessed on a Zeiss Contura G2 coordinate-measuring machine (CMM), and surface texture was evaluated with a TOPO 01P contact profilometer. The expanded measurement uncertainty (k = 2) was estimated based on duplicate test specimens. All drilled holes fell within the IT12 dimensional tolerance (PN-EN 22768-1:1999 grade c), with diameter oversizes ranging from +0.26 mm to +0.46 mm relative to the nominal bore. Cutting speed was identified as the dominant factor affecting both diameter oversize and cylindricity, which increased by 60% (from 0.10 to 0.16 mm) as vc rose from 10 to 30 m/min. Vibration accelerations increased nonlinearly between vc = 25 and 30 m/min (by a factor of 2.5×), indicating an approach to a structural resonance condition. The lowest surface roughness (Ra = 6.6 µm) was obtained at vc = 25 m/min. These findings establish clear physical baselines for tool deflection limits, demonstrating that managing dynamic process stability is vital for optimising macro-geometrical accuracy in the dry machining of cast iron alloys. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Accuracy Analysis of Holes Drilled in Ductile Cast Iron with an HSS Helical Drill Bit.
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Jun2026, Vol. 19 Issue 12, p2606. 19p.
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  Data: <searchLink fieldCode="DE" term="%22Machining%22">Machining</searchLink><br /><searchLink fieldCode="DE" term="%22Bits+%28Drilling+%26+boring%29%22">Bits (Drilling & boring)</searchLink><br /><searchLink fieldCode="DE" term="%22Nodular+iron%22">Nodular iron</searchLink><br /><searchLink fieldCode="DE" term="%22Surface+roughness%22">Surface roughness</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Controlling macro-geometrical errors in the dry drilling of ductile cast iron remains a critical challenge for sustainable and cost-efficient automotive component manufacturing. This paper investigates the influence of cutting speed (vc) and feed per revolution (fn) on the dimensional and shape accuracy of holes drilled in EN-GJS-500-7 ductile cast iron using an HSS DIN 338 helical drill (Ø 11.8 mm, Ceratizit) on an AVIA VMC800 CNC milling centre. A one-factor-at-a-time (OFAT) experimental design was applied: the feed effect was evaluated at vc = 10 m/min with fn ∈ {0.10, 0.15, 0.20} mm/rev, while the speed effect was evaluated at fn = 0.20 mm/rev with vc ∈ {10, 25, 30} m/min. Cutting forces, torques, and vibration accelerations were recorded using an HBM MSC 10 transducer and a PCB 356A01 tri-axial accelerometer. Hole geometry was assessed on a Zeiss Contura G2 coordinate-measuring machine (CMM), and surface texture was evaluated with a TOPO 01P contact profilometer. The expanded measurement uncertainty (k = 2) was estimated based on duplicate test specimens. All drilled holes fell within the IT12 dimensional tolerance (PN-EN 22768-1:1999 grade c), with diameter oversizes ranging from +0.26 mm to +0.46 mm relative to the nominal bore. Cutting speed was identified as the dominant factor affecting both diameter oversize and cylindricity, which increased by 60% (from 0.10 to 0.16 mm) as vc rose from 10 to 30 m/min. Vibration accelerations increased nonlinearly between vc = 25 and 30 m/min (by a factor of 2.5×), indicating an approach to a structural resonance condition. The lowest surface roughness (Ra = 6.6 µm) was obtained at vc = 25 m/min. These findings establish clear physical baselines for tool deflection limits, demonstrating that managing dynamic process stability is vital for optimising macro-geometrical accuracy in the dry machining of cast iron alloys. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19122606
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      – Code: eng
        Text: English
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        PageCount: 19
        StartPage: 2606
    Subjects:
      – SubjectFull: Machining
        Type: general
      – SubjectFull: Bits (Drilling & boring)
        Type: general
      – SubjectFull: Nodular iron
        Type: general
      – SubjectFull: Surface roughness
        Type: general
    Titles:
      – TitleFull: Accuracy Analysis of Holes Drilled in Ductile Cast Iron with an HSS Helical Drill Bit.
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            NameFull: Sójka, Radosław
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            NameFull: Ziarkowski, Piotr
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            – D: 15
              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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