Analysis of Burr Formation and Surface Roughness in Step Drilling of AA 2024– SiC - Fly Ash Hybrid Composites

Abstract

Metal Matrix Particulate Composites have become as a potential material particularly for automotive and aerospace applications. In view of the growing engineering applications of composites, the machining parameters must be optimized to achieve the good surface quality, reduced tool wear and cutting forces. In this paper, the effect of the feed, spindle speed and step drill material on the exit burr height and surface roughness have been analyzed. Experimental study was conducted for Al- SiC – fly ash hybrid composites which are fabricated through the stir casting method. Optimum drilling parameters were identified by employing Taguchi method and ANOVA techniques. The results were validated by confirmation test. Results revealed that feed, spindle speed and step drill materials are the most significant factors on the burr height and surface roughness. Dynamometer was used to evaluate the thrust that was being applied to the work piece when it was drilled.