Effect of Process Parameters on Surface Roughness, Thrust Force and Tool Wear of Coated HSS Tool during Drilling of Customized EN8 Alloy

Abstract

The present experimental study is to evaluate the performance of coated HSS tools during drilling of different hardness EN8 alloy. Four PVD coated HSS tools are used to drill different hardness specimen. ANOVA analysis of surface roughness, thrust force and tool is carried out for optimising the process. Results indicated that the tool 2 with R2 composition of TiSiNo+AP [AlCrN] performs better with respect to better surface finish thrust force and tool wear. It was found that, the favorable performance of the tools are in the order of tool 1,4 and 3 with composition of (TiSiNo[AlTiN/TiSiN]), (FTR[TiAlNmultilayer],+AP[AlCrN]) and (FTR[TiAlN multilayer]) respectively. Lowest and highest surface roughness is obtained for tool 2 and tool 3 with values of 1.55 and 1.85 micrometer, respectively. Also, minimum and maximum thrust force is obtained for tool 2 and tool 3 with 27 and 35 N respectively. Additionally, normal probability plot depict lower and higher thrust force for tool 2 and 3. During drilling tool 3 had resulted in higher tool wear accounting 68.69% while that of tool 2 remained 66.26%. The normal probability plot of tool 2 compared to tool 3 had 15% difference in contribution to quality of the machined alloy.