Multi response optimization of process parameters in titanium alloy minimum quantity lubrication drilling operation

Abstract

Abstract This work investigates the application of minimal quantity lubrication (MQL) in the drilling process, where a combination of liquid and air creates an aerosol in the form of a fine mist. This protective layer decreases friction and tool wear, hence improving overall efficiency. The study examines the conventional Gulfcut oil blend drilling technique to enhance drilling performance on the titanium alloy Ti-6Al-4V under MQL circumstances. The key drilling parameters, namely spindle speed (N), feed rate (F), and point angle (D), were analyzed using a Taguchi L16 orthogonal array. The experimental inquiry aimed to identify the most favorable conditions that lead to the least amount of torque (TQ), thrust force (TF), and surface roughness (SR). An Analysis of Variance (ANOVA) was used to examine the impact of control factors on drilling performance. The optimized drilling parameters led to a reduction in torque, thrust force, and surface roughness by 12.88%, 21.29%, and 25.76%, respectively. Furthermore, microstructure analysis demonstrated that the Gulfcut lubricant plays a pivotal role in reducing grain size during drilling. This research provides valuable insights into optimizing drilling conditions for titanium alloy using a conventional Gulfcut oil blend with MQL, aiming to reduce torque, thrust force, and surface roughness.