In order to reduce misalignment, enhance tight tolerance, and improve machining efficiency, a novel double cone integrated tool was developed and experimentally investigated during one-shot drilling of aluminum and aluminum alloy stacks in this paper. This special tool geometry can finish drilling, reaming, and countersinking processes at the same time. Its machining properties were comparatively evaluated with a standard twist drill (reference drill) by means of a series of experiments. Experimental results highlighted the influence of tool geometry on cutting force and vibration signals for drilling, reaming, and countersinking processes, respectively. The results indicated that the double cone integrated drill can induce a little larger thrust force than a reference drill due to its longer cutting edge. In addition, the chip morphologies generated by different processes and cutting variations also have been comparatively analyzed. The double cone drill under a larger feed rate was prone to produce smaller chips. Furthermore, the double cone drill can achieve smaller burrs, better surface integrity, and lighter tool wear compared with reference drill. The information obtained from this study can provide a better understanding of the one-shot drilling process and guidance for achieving higher efficiency and better hole quality.

为了减少不对中，提高紧公差和提高加工效率，本文开发了一种新型的双锥集成工具，并在铝和铝合金叠层的一次浇铸过程中进行了实验研究。这种特殊的刀具几何形状可以同时完成钻孔，铰孔和counter孔加工。通过一系列实验，使用标准麻花钻（参考钻）对它的加工性能进行了比较评估。实验结果强调了刀具几何形状分别对钻削，铰孔和and沉过程中切削力和振动信号的影响。结果表明，双锥一体式钻头由于其较长的切削刃，可比参考钻头产生更大的推力。此外，还比较分析了由不同工艺和切削变化产生的切屑形态。在较大进给速度下的双锥钻容易产生较小的切屑。此外，与参考钻相比，双锥钻可实现较小的毛刺，更好的表面完整性和更轻的工具磨损。从这项研究中获得的信息可以更好地理解单次钻孔过程，并为实现更高的效率和更好的孔质量提供指导。