Prediction and Optimization of Drilling Parameters in Drilling of AISI 304 and AISI 2205 Steels with PVD Monolayer and Multilayer Coated Drills

Abstract

Due to their high ductility, high durability, and excellent corrosion resistance, stainless steels are attractive materials for a variety of applications. However, high work hardening, low thermal conductivity, and high built-up edge (BUE) formation make these materials difficult to machine. Rapid tool wear and high cutting forces are the common problems encountered while machining these materials. In the present work, the application of Taguchi optimization methodology has been used to optimize the cutting parameters of the drilling process for machining two stainless steels: austenitic AISI 304 and duplex AISI 2205 under dry conditions. The machining parameters which were chosen to be evaluated in this study are the tool material, cutting speed, and feed rate, while, the response factors to be measured are the tool life (T), cutting force (F c ), and specific cutting energy (k s ). Additionally, empirical models were created for predicting the T, F c and k s using linear regression analysis. The results of this study show that AISI 2205 stainless steel has a shorter tool life, a higher cutting force, and a higher specific cutting energy than AISI 304 stainless steel. In addition, the Taguchi method determined that A 3 B 1 C 1 and A 3 B 3 C 1 (A 3 = TiN-coated twist drill, B 1 = 13 m/min, B 3 = 34 m/min, C 1 = 0.12 mm/rev) are the optimized combination of levels for the best tool life and the lowest cutting force, respectively. Meanwhile, the optimized combination of levels for all three control factors from the analysis, which provides the lowest specific cutting energy, was found to be A 3 B 1 C 3 (A 3 = TiN-coated twist drill, B 1 = 13 m/min, C 3 = 0.32 mm/rev) for both stainless steels.

Performance evaluation of the nano-silver added vegetable-oil-based cutting fluid in drilling process

“…Energy consumption increases with the increase in the feed rate parameter. With the increase in energy consumption, cutting forces also increase, and the effect of the feed rate on cutting forces becomes dominant [87][88][89]. The effectiveness of other parameters reduced due to the high effectiveness of the feed rate.…”

Evaluation of MQL performances using various nanofluids in turning of AISI 304 stainless steel

“…Also, the degree of influence was explained with the percentage contribution (PC), which is the product of division of each parameter's sum of squares (SS) onto their total. The higher the PC, the higher the effect a variable has on a measured response [40]. The analyses were carried out at confidence levels of 95% [41].…”

The Relationship between Surface and In-Depth Hardness for the Nitrocarburizing Treatment Process

“…For example, mono-and multi-layers have a very big effect on the lifetime and cutting ability of cutting tools [22][23][24][25]. The carbonized and nitrided surfaces also have a great effect to the microstructural, hardness, tribological, and corrosion behavior of parts [26][27][28][29].…”