Abstract
The main objective of this research is to investigate the effects of the cutting fluid and application mode (dry, mist and flood drilling) and its interaction with cutting parameters on part quality during the drilling of 6061-T6 aluminium alloys. The part quality criteria include the burr form and sizes, and surface finish as well as the cutting forces generated. A multi-factorial design (DOE) is used to plan test and statistical analyses are used to determine the effects of lubrication and cutting parameters on part quality. The parameters governing the part quality are different from those governing the cutting force; the burr height and the surface roughness are mostly influence by cutting speed, cutting fluid modes and feed rate while the cutting force is mainly determined by the feed rate. It is found that dry machining and mist machining can produce parts whose quality is comparable to what is obtained in wet machining, when optimal cutting conditions are used.
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