In the aeronautical industry, one-shot drilling of stacked materials is a widely adopted and established solution. However, ongoing discussions persist, particularly regarding the issue of interlayer gap formation that arises when two or more unsealed materials are drilled together. This study aims to present a simplified and reproducible theoretical model based on the equation of the elastic curve applied to structural schemes that discretize and describe the interlayer gap phenomenon in the drilling process. The model is designed to estimate the extent of the interlayer gap phenomenon and predict the clamping force required for its reduction when an end-effector is employed as a clamping device during the drilling of stacked sheets. Experimental and finite element analyses were conducted to validate the results of the proposed theoretical model. Each model was developed and applied to a real structural unit of a fuselage panel, considering actual boundary conditions in terms of structural constraints and geometric features of the assembly. The results obtained in this study demonstrate that the proposed one-dimensional theoretical model consistently aligns with experimental and numerical observations obtained through finite element analysis. This offers an effective and readily implementable solution in an industrial context as a tool for sizing the clamping force exerted by a clamping device.
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