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Experimental Study on Drilling of 5083 Al Alloy by Factorial Design

Excerpt

This paper reports the study on drilling process parameters on Aluminium alloy 5083 in terms of feed and thrust forces produced in drilled hole zone. Aluminium alloys are largely used in industrial fields and classified as very easy to machine even though the softer grades of this material tend to form a built up edge, which results in poor surface finish. Feed and thrust forces produced during drilling are often related to poor dimensional accuracy and undesired surface defects which is often a major concern for engineers on their design and fabrication. This research is to investigate the effect of drill bit diameter, spindle speed and feed rate on forces exerted during drilling process by Design of Experiment approach. The Factorial Design method is used to design the experiment and maximum numbers of trials are generated with the selected minimum levels of experiment factors and varying them simultaneously. The result shows that for feed force Ff, optimum cutting parameters obtained are low diameter, low feed rate, and high spindle speed which are 6mm, 30mm/min and 6000rpm respectively. This combination gives the lowest feed force and remains true for optimum thrust force in x direction, Fx too. The study shows that Ff and Fx are directly proportional to tool diameter and feed rate and inversely to speed. But for thrust force in y direction, Fy the optimum is found at low tool diameter, high spindle speed but medium feed rate.

  • Abstract
  • Key Words
  • 1. Introduction
  • 2. Experimental Procedure
  • 3. Results And Discussion
  • 4. Summary
  • References

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