Optimization of Process Parameters with Minimum Thrust Force and Torque in Drilling Operation Using Taguchi Method

Suleyman Neseli

doi:10.1155/2014/925382

Abstract

This research outlines the Taguchi optimization methodology, which is applied to optimize cutting parameters in drilling of AISI 1040 steel. The drilling parameters evaluated are cutting speed, feed rate, and helix angle. Series of experiments are conducted to relate the cutting parameters on the thrust force and torque. L27(313) orthogonal array, signal-to-noise ratio is employed to analyze the influence of these parameters on thrust force and torque during drilling. Analysis of variance (ANOVA) is used to study the effect of process parameters on machining process. The study shows that the Taguchi method is suitable to solve the stated problem with the minimum number of trials. The main objective is to find the important factors and combination of factors that influence the machining process to achieve low thrust force and torque. The analysis of the Taguchi method indicates that the feed rate is the most significant factor affecting the thrust force, while the cutting speed contributes the most to the torque.

Highlights

Metal cutting operations, such as drilling, turning, and milling, are widely used in manufacturing to produce a variety of mechanical components
The drilling tests were carried out using twist drills in three helix angles at cutting speeds and feed rates in three levels
Statistically designed experiments based on Taguchi methods were performed using L27(313) orthogonal array to analyze the thrust force and torque as response variables, respectively

Summary

Introduction

Metal cutting operations, such as drilling, turning, and milling, are widely used in manufacturing to produce a variety of mechanical components. Hole drilling is by far the most widely used process in manufacturing [1]. Drilling operations are mainly dependent on the cutting parameters and drilling tools. The critical thrust force and torque at the onset of unproductiveness play the major role, and those are correlated with the process parameters. Among the scientific problems in drilling, determining the thrust force and torque for any drill geometry, especially the variation of helix angle, remains an issue. The understanding of parameter dependency on thrust force and torque can bring some strategic information to optimize the drilling operations. It is necessary to optimize the cutting parameters to obtain an extended tool life and a better productivity, which are influenced by cutting thrust and torque [2,3,4]

Methods

Results

Conclusion