7 - Minimising burr size in drilling: integrating response surface methodology with particle swarm optimisation

Abstract

The exit burr in drilling has several undesirable features with regard to product quality and functionality. Hence, selection of optimal process parameters for minimising burr size at production stage is essential to reduce the deburring cost and time. This chapter highlights the application of particle swarm optimisation (PSO) for burr size minimisation in drilling of AISI 316L stainless steel. The experiments were planned as per Box-Behnken design (BBD), and mathematical models for burr height and burr thickness were developed using response surface methodology (RSM) with cutting speed, feed, drill diameter and point angle as process parameters. The developed burr size models were then employed with PSO to determine the best combination of process parameters for a given drill diameter, which results in minimal burr height and burr thickness. The importance of larger point angle for bigger drill diameter values for minimising burr size is clearly evidenced in PSO simulation results.