Optimization of cutting parameters by thrust force and time for drilling of aluminum 2024 T351

Yunus Zubeyir Turgut; Murat Ozsoy

doi:10.1515/mt-2023-0001

Article

Optimization of cutting parameters by thrust force and time for drilling of aluminum 2024 T351

Yunus Zubeyir Turgut
Yunus Zubeyir Turgut graduated from Sakarya University, Department of Mechanical Engineering. In the same year, he started his master’s degree education at Sakarya University, Department of Machine Design and Manufacturing. He graduated with his master’s degree in January 2023.
and Murat Ozsoy
Dr Murat Ozsoy received his bachelor’s degree in 1996 in Mechanical Engineering from Balıkesir University, his master’s degree in 1998 and his PhD. degree in 2005 in Mechanical Engineering from Sakarya University, Türkiye. He is currently an associate professor in the Department of Mechanical Engineering at Sakarya University. His research interests include CAD, CAM, CAE, and composite materials.

Published/Copyright: July 3, 2023

Published by

Become an author with De Gruyter Brill

Submit Manuscript Author Information

From the journal Materials Testing Volume 65 Issue 8

Abstract

In this study, the cutting parameters were optimized according to the thrust force and operation time in the drilling of Al 2024 T351 alloy, which is preferred in the aerospace industry and therefore subjected to thousands of drilling processes with liquid cooling. Cutting speed (70, 90, and 110 m min⁻¹) and feed rate (0.08, 0.1, and 0.12 mm tooth⁻¹) were considered cutting parameters. Experiments were performed three tool types (HSS, HSSE-Co5, HSSE-Co5 TiAlN coated). Taksan TMC-700 V CNC vertical machining center with FANUC control panel was used for drilling, and ESIT AX3 load cell and NI cDAQ-9188, data acquisition system, were used for data collection. Signal noise was reduced by applying the exponential smoothing method to all force data obtained in the experiments. The maximum forces in the machining direction (z-axis) were determined for each hole. The time was calculated during the computer aided manufacturing process. Response surface optimizations, variance analyses (ANOVA), and regression analyses were performed using these determined maximum thrust forces and measured time.

Keywords: drilling; machining time; optimization; RSM; thrust force

Corresponding author: Murat Ozsoy, Department of Mechanical Engineering, Sakarya University, Sakarya Üniversitesi Mühendislik Fakültesi Makine Mühendisliği Bölümü, Serdivan, Sakarya, 54050, Türkiye, E-mail: ozsoy@sakarya.edu.tr

About the authors

Yunus Zubeyir Turgut

Yunus Zubeyir Turgut graduated from Sakarya University, Department of Mechanical Engineering. In the same year, he started his master’s degree education at Sakarya University, Department of Machine Design and Manufacturing. He graduated with his master’s degree in January 2023.

Murat Ozsoy

Dr Murat Ozsoy received his bachelor’s degree in 1996 in Mechanical Engineering from Balıkesir University, his master’s degree in 1998 and his PhD. degree in 2005 in Mechanical Engineering from Sakarya University, Türkiye. He is currently an associate professor in the Department of Mechanical Engineering at Sakarya University. His research interests include CAD, CAM, CAE, and composite materials.

Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
Research funding: None declared.
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.

References

[1] A. Yıldız, “Simulation of drilling operation and examination of mechanical stresses according to variation in cutting parameters in drilling operations,” PhD. dissertation, Institute of Natural Sciences, Gazi University, Ankara, Turkey, 2021.Search in Google Scholar

[2] M. Nouari, G. List, F. Girot, and D. Géhin, “Effect of machining parameters and coating on wear mechanisms in dry drilling of aluminium alloys,” Int. J. Mach. Tool Manufact., vol. 45, nos. 12–13, pp. 1436–1442, 2005, https://doi.org/10.1016/j.ijmachtools.2005.01.026.Search in Google Scholar

[3] Z. Zhu, B. He, and J. Chen, “Evaluation of tool temperature distribution in MQL drilling of aluminum 2024-T351,” J. Manuf. Process., vol. 56, pp. 757–765, 2020, https://doi.org/10.1016/j.jmapro.2020.05.029.Search in Google Scholar

[4] E. P. Bonhin, S. David-Müzel, E. S. Guidi, E. C. Botelho, and M. V. Ribeiro, “Influence of drilling parameters on thrust force and burr on fiber metal laminate (Al 2024-T3/glass fiber reinforced epoxy),” Procedia CIRP, vol. 101, pp. 338–341, 2020, https://doi.org/10.1016/j.procir.2021.02.035.Search in Google Scholar

[5] L. Kutlu, “Experimental investigation and taguchi optimization for the effect of cutting parameters on the drilling of Al 2024-T4 alloy with diamond like carbon coated drills,” MSc. thesis, Institute of Natural Sciences, Marmara University, Istanbul, Türkiye, 2009.Search in Google Scholar

[6] Y. Landon, A. Lacombe, L. A. K. Souop, et al.., “Impact of the drilling process on the surface integrity and residual fatigue strength of 2024-T351 aluminum parts,” Procedia CIRP, vol. 108, pp. 459–464, 2022, https://doi.org/10.1016/j.procir.2022.03.072.Search in Google Scholar

[7] A. Çakır, “Investigation of the effects of cooling methods on machining performance in drilling holes in AA 7075 and AA 2024 aluminum materials,” PhD. dissertation, Gazi University, Ankara, Türkiye, 2015.Search in Google Scholar

[8] M. Aamir, K. Giasin, M. Tolouei-Rad, et al.., “Effect of cutting parameters and tool geometry on the performance analysis of one-shot drilling process of aa2024-t3,” Metals, vol. 11, no. 6, pp. 854–866, 2021, https://doi.org/10.3390/met11060854.Search in Google Scholar

[9] M. E. Korkmaz, R. Çakıroğlu, N. Yaşar, R. Özmen, and M. Günay, “Analysis of thrust force by finite element method in drilling Al 2014 aluminum alloy,” El-Cezeri J. Sci. Eng., vol. 6, no. 1, pp. 193–199, 2019, https://doi.org/10.31202/ecjse.449701.Search in Google Scholar

[10] G. Navaneethakrishnan, B. Sureshkumar, R. Palanisamy, M. Bajaj, H. M. Zawbaa, and S. Kamel, “Effect of cryogenic treatment on drill tool for enhancing metal cutting operation of aluminium alloy IS737.Gr19000,” J. Mater. Res. Technol., vol. 18, pp. 1488–1501, 2022, https://doi.org/10.1016/j.jmrt.2022.03.069.Search in Google Scholar

[11] N. Yaşar, “Thrust force modelling and surface roughness optimization in drilling of AA-7075: FEM and GRA,” J. Mech. Sci. Technol., vol. 33, no. 10, pp. 4771–4781, 2019, https://doi.org/10.1007/s12206-019-0918-5.Search in Google Scholar

[12] E. Bahce and C. Ozel, “Influence of a stepped feed rate on burr formation when drilling Al-5005,” Mater. Test., vol. 60, no. 3, pp. 316–324, 2018, https://doi.org/10.3139/120.111154.Search in Google Scholar

[13] M. Aamir, K. Giasin, M. Tolouei-Rad, and A. Vafadar, “A review: drilling performance and hole quality of aluminium alloys for aerospace applications,” J. Mater. Res. Technol., vol. 9, no. 6, pp. 12484–12500, 2020, https://doi.org/10.1016/j.jmrt.2020.09.003.Search in Google Scholar

[14] N. Ozsoy, “Prediction and optimization of thrust force during the drilling of AISI 2080 steel,” Mater. Test., vol. 64, no. 4, pp. 602–609, 2022, https://doi.org/10.1515/mt-2021-2098.Search in Google Scholar

[15] H. Tanabi, “Machinability of alloy ductile iron and forged 16MnCr5 steel,” Mater. Test., vol. 64, no. 3, pp. 455–462, 2022, https://doi.org/10.1515/mt-2021-2027.Search in Google Scholar

[16] F. Kara and A. Takmaz, “Optimization of cryogenic treatment effects on the surface roughness of cutting tools,” Mater. Test., vol. 61, no. 11, pp. 1101–1104, 2019, https://doi.org/10.3139/120.111427.Search in Google Scholar

[17] A. M. Kumar, R. Parameshwaran, V. Krishnaraj, and R. Rathanasamy, “Effects of thrust force variation during the drilling of pure and chemically treated Kevlar based polymer composites,” Mater. Test., vol. 61, no. 9, pp. 907–913, 2019, https://doi.org/10.3139/120.111392.Search in Google Scholar

[18] A. Saravanakumar, P. Sreenivas, S. Vijaya kumar, U. Pradeep kumar, and L. Rajeshkumar, “Optimization of drilling process parameters for self-lubricants reinforced aluminium metal matrix composites,”Mater. Today: Proc., vol. 52, pp. 1461–1465, 2022, https://doi.org/10.1016/j.matpr.2021.11.196.Search in Google Scholar

[19] H. Gokce, “Investigation of drilling performance of CuZn15 brass material,” Eur. J. Sci. Technol., vol. 22, pp. 32–42, 2021, https://doi.org/10.31590/ejosat.849503.Search in Google Scholar

[20] Aerospace Specification Metals Inc, Aluminum 2024-t351. Available at: https://asm.matweb.com/search/SpecificMaterial.asp?bassnum=ma2024t4 [accessed: Dec. 20, 2022].Search in Google Scholar

Published Online: 2023-07-03

Published in Print: 2023-08-28

You are currently not able to access this content.

Articles in the same Issue

https://doi.org/10.1515/mt-2023-0001

Keywords for this article

drilling; machining time; optimization; RSM; thrust force