Experimental and Statistical Investigation of Drilling of Aisi 1040 Steel at Dry and Wet Conditions

Abstract

AISI 1040 steel is widely used in the machinery and manufacturing industries and is used in a variety of machine parts, automotive parts, molds, fixtures and many other areas. Technological developments in the field of machining in recent years have led to many problems affecting machining performance. Drilling is one of the most important machining operations. In this study effect of drilling parameters such as cutting speed (15, 20 m/min), feed rate (0.1, 0.15 mm/tooth), type of drill (HSS-E, HSS-E TiN coated), drilling type (standard, pecking) and cooling type (liquid, air) were examined on AISI 1040 steel. Parameters' effects on surface roughness were investigated. Experiments were planned according to L8 orthogonal array. Optimum conditions were found via Taguchi's Signal/Noise analysis. Probability analysis was performed to discover the distribution of the measured/calculated values of the results. Lastly, confirmation tests were conducted to control the success of the optimization. The optimal conditions for surface roughness were observed at A1B2C2D1E2 (i.e., cutting speed: 15m/min, feed rate: 0.15mm/tooth, cooling type: liquid, drilling type: standard, and type of drill: HSS-ETiN coated).

Investigation of Drilling Performance of Reinforced Polyamide 6 Polymer Composite

“…Since the Ra and deformation factor were required to be low in the drilling of PA6+20CF composite materials, the "smaller-better" performance characteristic was chosen for the S/N ratio. The Equation (1) used to calculate the S/N ratios is given below [13,15,[35][36].…”

“…The analysis of variance (ANOVA) was performed, to determine the effect of differences between the factors affecting the process for PA6+20CF polymer composite. The effects of parameters in ANOVA are calculated by comparing the Fvalues of each factor [13]. As seen from Table 9, drill bit material is the most effective parameter on surface roughness and outlet deformation factor, while cutting speed only effect the inlet deformation factor.…”

“…In the experimental study, optimal results of surface roughness, inlet, and outlet deformation factors according to the independent variables of cutting speed, feed rate and drill bit material were obtained by using the Taguchi optimization method. In addition, the validity of the statistically derived ideal parameters was tested with the confirmation experiments [9,13]. Relation between the statistically prediction levels and confirmation experiment were given in Table 13.…”

“…Early in the 60s, Genichi Taguchi's new methodology is start to use due its success in improving all kind of industrial performance. The small number of experiments, easy implementation and easy evaluation of the variables are the features that increase the prevalence of the Taguchi method [13][14][15][16].…”