Mathematical Modeling and Analysis of Surface Roughness in Drilling of AISI 1055 Steel Using Response Surface Methodology

Abstract

It is still indispensable to explore the effects of peck depth and its interaction with speed, and feed in widely preferred flood coolant drilling process with aspect ratio more than 5 by using the much accurate response surface method. A three-parameter, five-level design matrix is developed using central composite inscribed design of response surface method. Experiments are performed on vertical machining center in flood coolant environment using the canned cycles and experimental results are analyzed in detail using ANOVA, contour plots, interaction plots, main effect plots, and micrographs. Influence of spindle speed, feed rate is observed to be of similar nature on surface roughness, while the effect of peck depth differs at both the ends of hole. Minimum surface roughness at bottom of hole is occurred at comparatively lower spindle speed (3800 rpm) and peck depth (7.0 mm). Even though peck depth has shown least influence on surface roughness, proper peck depth has contributed in improving the surface finish.