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.　©　2020,　Springer-Verlag　London　Ltd.,　part　of　Springer　Nature.