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Investigation of Thrust Force, Drill Bit Temperature and Burr Height in the Drilling of Aluminum Alloy Used in Ammunition Wing Drive Systems

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Abstract

In this present study, the effect of drilling parameters and carbide drill bits in drilling of Al 5083 H116 alloy was investigated. The drilling tests were carried out using various carbide drill bits at 40, 80, 120, 160 m/min cutting speeds and 0.025, 0.050, 0.075, 0.100 feed rates. The experimental design was performed using the Taguchi’s L16 orthogonal array. The drilling tests were carried out without using coolant and it was aimed to minimize the thrust force, drill bit temperature and burr formation at the hole exit. Simultaneous optimization was performed using Taguchi-based Grey Relational Analysis (GRA). Using the data obtained from the drilling tests, mathematical models with Response Surface Methodology (RSM) and predicted values with Artificial Neural Networks (ANN) were obtained. It was observed that there was a significant increase in thrust force and burr height with increasing feed rate. In addition, the drill bit temperature was adversely affected by the increasing values of the cutting speed. The most effective control factors according to the analysis of variance were found to be the feed rate with 99.9 % for thrust force, cutting speed with 91.54 % for drill bit temperature and feed rate with 79.78 % for burr height. As a result of GRA, the feed rate with a value of 0.3612 was determined as the most important control factor, moreover, according to RSM results, the optimum parameters were 40 m/min cutting speed, 0.025 mm/rev feed rate and drill bit 1. The reliability of the developed mathematical model was confirmed with determination coefficients of 99.1 % for the thrust force, 98.8 % for the drill bit temperature and 99.7 % for the burr height. With ANN, a prediction success rate of 99.8 % for thrust force, 99.8 % for drill bit temperature and 99.6 % for burr height was achieved.

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Acknowledgements

The author would like to thank Çankırı Karatekin University Scientific Research Project Unit for provision of funding with the Project MYO801202B32.

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  1. Engineering Faculty, Mechanical Engineering, Çankırı Karatekin University, Çankırı, Turkey

    H. Gökçe & M. A. Biberci

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Gökçe, H., Biberci, M.A. Investigation of Thrust Force, Drill Bit Temperature and Burr Height in the Drilling of Aluminum Alloy Used in Ammunition Wing Drive Systems. Exp Tech 46, 691–705 (2022). https://doi.org/10.1007/s40799-021-00501-0

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