Abstract
In this research, experimental studies were based on drilling with solid carbide tools and the material used was Al7075. The study primarily focused on investigating the effects of machining parameters (cutting speed, feed rate, diameter of the tool) on the thrust force (Fz) and the cutting torque (Mz) when drilling an Al7075 workpiece. The experimental data were analyzed using the response surface methodology (RSM) with an aim to identify the significant factors on the development of both the Fz and Mz. The application of the mathematical models provided favorable results with an accuracy of 3.4% and 4.7%, for the Fz and the Mz, respectively. Analysis of variance (ANOVA) was applied in order to examine the effectiveness of the model, and both mathematical models were established and validated. The equations derived proved to be very precise when a set of validation tests were executed. The importance of the factors’ influence over the responses was also presented. Both the diameter of the cutting and the feed rate were found to be the factors of high significance, while cutting speed did not affect considerably the Fz and Mz in the experiments performed.
Highlights
A majority of products are directly or indirectly related to the metal cutting processes during their production processes
This paper presents a study of the Al7075 drilling process when using solid carbide tools with different diameters
The aim of this study was the generation of mathematical models for the prediction of the thrust force (Fz) and cutting torque (Mz) related to the diameter of the drilling tool and other crucial manufacturing parameters during the drilling process
Summary
A majority of products are directly or indirectly related to the metal cutting processes during their production processes. From the most commonly used processes, such as milling, turning, tapping and so forth, drilling constitutes the most commonly used. A significant number of holes are necessary for the assembly of different parts in order to be connected each other and develop the product itself. Many researchers have developed empirical methodologies based on statistics, which can be used to learn the interactions between manufacturing factors. RSM is a collection of an empirical modeling approach for defining the relationship between a set of manufacturing parameters and the responses. Different criteria are used and the significance of these manufacturing parameters on the coupled responses are examined
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