Abstract
This article presents an attempt to solve the problem of the formation of burrs and drilling caps in the process of drilling in difficult-to-cut materials, specifically in the titanium alloy Ti-6Al-4V. In order to eliminate these phenomena, a chamfer of specific length and angle was made on FANAR drill’s margin. Taguchi and ANOVA methods were used to plan and analyze the experiment aimed at determining the optimal geometry of the modified drill. Chamfer with a length of 2 mm and an angle of 10° was selected. In the next stage of research, the values of cutting forces and burr heights obtained during drilling with the original and modified drill were compared for three different feed rate values. It turned out that the introduced changes significantly reduced both the axial cutting force (22–23%) and the height of burrs (10–22%) and caused the complete elimination of the presence of drilling caps. Additionally, a positive correlation between the cutting force and the burr size was found.
Highlights
Rapid development of industry entails the need to use new types of materials and to improve the methods of their processing
Abdelhafeez et al [7] showed that parameters such as feed and cutting speed have a significant impact on the size of burrs in the drilling process
The burr formation phenomena were recorded using a Research cutting forces to be measured during the drilling process
Summary
Rapid development of industry entails the need to use new types of materials and to improve the methods of their processing. Abdelhafeez et al [7] showed that parameters such as feed and cutting speed have a significant impact on the size of burrs in the drilling process. Production efficiency decreases while its costs increase It seems that the method of minimizing the phenomenon of burr formation during the drilling process would be a better solution. The most common method is to optimize the process by appropriate selection of the drilling parameters, the correct choice of the tool material and geometry and the control of its wear. If the material is torn around the edge of the resulting hole, the burr is smaller, but the drilling cap is formed [5]
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