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Article
Publication date: 16 February 2023

Hüseyin Gökçe and Mehmet Ali Biberci

This study aims to obtain the lowest surface roughness (Ra) and drill bit adhesion values (AV) depending on the change in control factors (cutting speed-Vc, feed rate-f and drill…

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Abstract

Purpose

This study aims to obtain the lowest surface roughness (Ra) and drill bit adhesion values (AV) depending on the change in control factors (cutting speed-Vc, feed rate-f and drill bit-D) during drilling of the Al 5083 H116 alloy. Low roughness values increase the fatigue strength of the final part and affect tribological properties such as lubrication and friction. In the machining of ductile materials, the AV increases the Ra value and negatively affects the tool life.

Design/methodology/approach

Drilling tests were conducted using Taguchi L16 orthogonal array. The experimental measurement findings for Ra and AV were adjusted utilizing the Grey Relational Analysis (GRA), the Response Surface Method (RSM) and Artificial Neural Networks (ANN) to generate prediction values. SEM detected drill-tip adhesions and chip morphology and they were analyzed by EDX.

Findings

Ra and AV increased as the f increased. Vc affects AV; 86.04% f on Ra and 54.71% Vc on AV were the most effective control parameters. After optimizing Ra and AV using GRA, the f is the most effective control factor. Vc: 120 m/min, f: 0.025 mm/rev and D2 were optimal. ANN predicted with Ra 99.6% and AV 99.8% accurately. Mathematical models are obtained with RSM. The increase in f increased AV, which had a negative effect on Ra, whereas the increase in Vc decreased the adhesion tendency. With the D1 drill bit with the highest flute length, a relatively lower Ra was measured, as it facilitates chip evacuation. In addition, the high correlations of the mathematical models obtained indicate that the models can be used safely.

Originality/value

The novelty of this study is to determine the optimum drilling parameters with GRA and ANN for drilling the necessary holes for the assembly of ammunition wing propulsion systems, especially those produced with Al 5083 H116 alloy, with rivets and bolts.

Details

Multidiscipline Modeling in Materials and Structures, vol. 19 no. 2
Type: Research Article
ISSN: 1573-6105

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Article
Publication date: 4 August 2022

Meltem Altin Karataş, Hasan Gökkaya, Sıtkı Akincioğlu and Mehmet Ali Biberci

The purpose of this study is to optimize processing parameters to get the smallest average surface roughness (Ra) and delamination damage (Fd) values during drilling via abrasive…

174

Abstract

Purpose

The purpose of this study is to optimize processing parameters to get the smallest average surface roughness (Ra) and delamination damage (Fd) values during drilling via abrasive water jet (AWJ) of the glass fiber-reinforced polymer composite material produced at [0°/90°]s fiber orientation angles.

Design/methodology/approach

Drilling experiments were done via AWJ with three-axis computer numerical control (CNC) control system. Machine processing parameters such as water pressure of 3,600, 4,300, 4,800 and 5,300 bar; stand-off distance of 1, 2, 3 and 4 mm; traverse rate of 750, 1,500, 2,000 and 3,000 mm/min; and hole diameters of 8, 10, 12 and 14 mm have been selected. The effects of processing parameters in drilling experiments were investigated in conformity with the Taguchi L16 orthogonal array and the data obtained were analyzed using Minitab 17 software. The signal/noise (S/N) ratio was taken as a basis for evaluating the test results. Optimum processing conditions were determined by calculating the S/N ratio for both Ra and Fd in conformity with the “smaller is better” approximation. The effects of processing parameters on Ra and Fd were statistically investigated using analysis of variance, S/N ratio and Taguchi-based gray relational analysis. Ra and Fd were predicted by evaluating with the ANN model and were predicted with the least amount of error.

Findings

It has been determined that the most effective parameter for Ra and Fd is the water pressure and then the stand-off distance.

Originality/value

The novel approach is to reduce cost and the time spent by using Taguchi optimization as a result of AWJ drilling the material in this fiber orientation [0°/90°]s.

Details

Multidiscipline Modeling in Materials and Structures, vol. 18 no. 4
Type: Research Article
ISSN: 1573-6105

Keywords

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