Optimization of coated friction drilling tool for a FML composite

Abstract

ABSTRACT In the present research, an attempt was made to determine the suitable coated tool for drilling AA5052 nano hybrid sandwich sheet using Response Surface Methodology (RSM) and Taguchi method. The work aims at minimizing thrust force and torque on a friction drilling tool for drilling holes. Plasma Nitriding, Liquid Nitriding, and PVD Titanium Nitride (TiN) coating are applied on H13 steel tool material. Results indicate that for achieving minimum torque and thrust force, feed of 50 mm/rev and spindle speed of 4000 rpm to be used during drilling. Whereas, to reduce the drilling time, feed has to be increased up to 200 mm/rev. The maximum bushing height is 5.6 mm for Liquid Nitrided tool at 2500 rpm, 50 mm/rev, and 5.4 mm for PVD TiN-coated tool at 3000 rpm, 200 mm/rev, whereas 4.71 mm is the minimum bushing height for Plasma Nitrided tool at 3500 rpm, 150 mm/rev. The result obtained from RSM was compared with Minitab response optimizer and Harmonic Search Algorithm. PVD TiN coated tool exhibited the best performance in terms of low thrust force value of 84.70 N at 4000 rpm, 50 mm/rev and low torque value of 1.5395 N-m at 2500 rpm, 50 mm/rev.