Experimental study on drilling burr formation minimization and parameters optimization using BBO algorithm

Abstract

In the drilling process, unwanted materials which extend beyond the work-piece surface are called burr. The main objective is to find out optimum drilling condition which minimize the burr height and burr thickness. For this purpose, an experimental study has been performed on aluminium alloys using an HSS twist drill according to L27 experimental run. For this experiment the input process parameters spindle speed, feed rate and depth inside backup support and for the response parameters burr height and burr thickness have been considered. The response surface methodology-based regression equation has been developed for burr height and burr thickness using this experimental dataset and compared with the experimental result that shows a close matching. The effect of the input process parameters i.e. spindles speed; feed rate and depth inside backup support are presented in contour plots to understand the effect of them. Finally, optimum drilling process has been obtained by using Biogeography Based Optimisation (BBO) technique to minimize the burr height and burr thickness. From BBO optimization it cleared that minimum burr height is found at a speed of 320 rpm, feed of 0.08 mm/rev and depth inside backup support of 0.20 mm, also minimum burr thickness is produced at a speed of 125 rpm, feed of 0.9395 mm/rev and depth inside backup support of 0.56 mm.