Fuzzy Logic-Based Prediction of Drilling-Induced Temperatures at Varying Cutting Conditions along with Analysis of Chips Morphology and Burrs Formation

Asim Ahmad Riaz,Riaz Muhammad,Mohammed Alkahtani,Waseem Akram,Naveed Ullah,Ghulam Hussain

doi:10.3390/met11020277

Abstract

Friction and plastic deformation at the tool–chips interaction during a dry drilling process results in temperature rise and promotes tool wear and surface roughness. In most of the components produced in industries, a drilling process is used to make a hole for final assembly. Therefore, knowledge of temperatures produced during drilling operation at various machining input parameters is required for the best quality product. A fuzzy logic-based algorithm is developed to predict the temperature generated in the drilling process of AISI 1018 mild steel. The algorithm used speed and feed rate of the drill bit as input parameters to the fuzzy domain. A set of rules was used in the fuzzy domain to predict maximum temperature produced in the drilling process. The developed algorithm is simulated for various input speed and feed rate parameters and was verified through the maximum temperature measured during drilling of the studied material at selected speed–feed combinations. Experiments were conducted to validate the results of developed fuzzy logic-based algorithm by using non-contact infrared pyrometer for drilling of AISI 1018 steel. A good agreement between the predicted and experimentally measured maximum temperature was observed with an error less than 6%. It is found that temperature increases with increase in cutting speed and feed rate. Size of roll back burr formation at the hole perimeter significantly increases with increase in drill speed and feed rate. Segmental continuity in spiral or helix chips morphology is more at low feed and high cutting speed. Chip radius increases with increase in feed rate and results in damaging of the machined surface and causes burr formation while the radius decreases with cutting speed along with improved hole surface finish.

Highlights

AISI 1018 steel belongs to the steel class of material kingdom and has a properties profile compatible with most of the engineering applications
It can be seen that rise in maximum temperature is comparatively less with increase in feed rate as compared to cutting speed
If we focus on height and thickness of burrs attached with hole periphery, they increase with increase in feed rate while cutting speed has no significant effect on burrs height and thickness

Summary

Introduction

AISI 1018 steel belongs to the steel class of material kingdom and has a properties profile compatible with most of the engineering applications. Due to excellent metallurgical and mechanical properties, this alloy is extensively used in making gears, shafts, spindles, pins, rods, sprocket chains, and other machine tools and components. It has good machinability, weldability, and mechanical properties [1]. Drilling is one of the principal machining processes and is used to create holes. In the aerospace and automobile sectors, conventional drilling is economically viable to create holes in mechanical parts/geometries [2]. Air vehicles and fast-moving objects are subjected to constant vibration and shock loads where fastener holes are prone to stress concentration and fatigue loads [3]. Fatigue load compromises reliability of aircraft and other vehicles

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Conclusion