Abstract
From ancient days to till today manufacturing industries, especially making of holes on the parts during drilling process for precision assembling of parts facing problems with burr formation. Drilling operation is one of the finishing operation in the production cycle, removing of burrs during drilling process is a time consuming and non-value added process to the manufacturing sector. So reducing the size of burrs is the main aim of the present study. In the present work, optimization of burr size is considered during drilling of aluminium 7075 alloy. From Grey relational grades of responses selected optimal combination of parameters to attain multiple performance characteristics of responses with a corresponding higher grey relational grade. For identifying the most significant input parameters that influence the output responses ANOVA is conducted. Finally, observations reveals that feed rate, point and clearance angles are the most influential factors on burr size and also experimental results divulge that the lower the thrust force causes to decrease the burr height. The proposed approach is helpful to the budding entrepreneurs in the related areas to select optimal combination of drilling parameters to attain multiple performance characteristics of responses especially in burr size to prevent the post finishing operations.
Highlights
The burr, which is a plastically deformed material, engendered during drilling is a preventable output and often lowers the surface quality, diminishes the product life and acceptability of the product
To know the weightage of influencing input parameters over the output responses in level wise, the graphs are drawn between the levels of input parameters versus average grey relational grades
The relative importance and statistical significance of the main and interaction effects between process input parameters to influence the output responses are identified from analysis of variance (ANOVA) in the order of decreasing contribution of each parameter
Summary
The burr, which is a plastically deformed material, engendered during drilling is a preventable output and often lowers the surface quality, diminishes the product life and acceptability of the product. Total elimination of burrs during drilling process is a trivial task, with proper selection of process parameters, it can be curtailed. Selection of process parameters according to workpiece material and hole quality requirement is critical for the minimization or prevention of burr formation. The burr, an unintended outcome of machining processes, has been a widely recognized problem in the industry. Burrs ruins the integrity of design of the part. All these side effects causes unnecessary cost to the industry in various forms such as additional machining, compensation, service, redesign and collateral damage on the company reputation. In most cases, it is a must either to remove or to secure the burr in order to prevent from being detached as of the part
Sign-in/Register to view highlights & summary 
Published Version (
Free)
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call