Multivariate modelling of AA6082-T6 drilling performance using RSM, ANN and response optimization

Abstract

The AA6082-T6 was experimentally studied in the present research with respect to the drilling performance. Drill diameter, cutting speed and feed rate were examined, using a full factorial design. Mathematical modelling of the process was carried out using the Response Surface Methodology (RSM) as well as the Artificial Neural Network (ANN) techniques. The output results in terms of cutting force, torque and surface roughness, revealed high levels of correlation between the experimental and the predicted data. Specifically, the Mean Absolute Percentage (MAPE) values using RSM compared to the ones of the experiments, were equal to 2.14%, 3.49% and 6.16% for Fz, Mz and Ra respectively. The equivalent MAPEs between the ANN and the experiments were found to be 2.19%, 1.82% and 2.85% accordingly. Moreover, the most significant terms were revealed, being the interaction D×f for the thrust force and the torque with contribution percentages equal to approximately 44% and 42% respectively, and the term D2 for the surface roughness with 51%. The evaluation of the machining parameters, identified their significance, enabling the selection of the optimal cutting parameters, which were obtained by the desirability function, taking into account the importance of the generated surface quality and the reduction of cost. The solutions given by this approach, pointed out the Ø9 tool, coupled with Vc = 50m/min and f = 0.15mm/rev as a well-balanced combination, whereas the Ø9.9 tool used under the same conditions, yielded the best possible surface quality (appr. 0.2 microns).