Optimization of the Cutting Parameters for Drilling Magnesium Alloy AZ 91

Yunus Kayir

doi:10.3139/120.110523

Article

Optimization of the Cutting Parameters for Drilling Magnesium Alloy AZ 91

Yunus Kayir

Published/Copyright: October 1, 2014

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From the journal Materials Testing Volume 56 Issue 1

Abstract

In this study, machinability of AZ 91D magnesium alloy, which has been widely used in automotive and aircraft industries, was investigated by using HSS and carbide tools at dry cutting conditions. Taguchi's L₁₈ (2**1 3**2) mixed model was used for the experiments. Drilling parameters such as feed rate, spindle speed and cutting tool were optimized according to the multiple responses (diametral error, circularity and surface roughness) by grey relational analysis. The effects of machining parameters and their interactions on the hole diameter, circularity and surface roughness were determined. The analysis of Taguchi and ANOVA indicated that the influence of drill material on the surface roughness of the drilled hole was high, but on the hole diameter and circularity it was low. Furthermore, the results of grey relational analysis revealed that optimal combination of the drilling parameters (0.3 mm/rev feed rate, carbide tool and 3000 rpm spindle speed) can be used to obtain the minimum diametral error, circularity error and surface roughness.

Kurzfassung

In der diesem Beitrag zugrunde liegenden Studie wurde die maschinelle Bearbeitbarkeit der Magnesiumlegierung AZ 91 D, die eine breite Anwendung in der Automobil- und Flugzeugindustrie erfährt, untersucht, indem HSS- und Carbid-Werkzeuge unter trockenen Schneidbedingungen eingesetzt wurden. Für die Experimente wurde Taguchi's gemischtes Modell L₁₈ (2**1 3**2) eingesetzt. Die Bohrparameter, wie die Zufuhrrate, die Spindelgeschwindigkeit und das Schneidwerkzeug wurden entsprechend der multiplen Antworten (diametraler Fehler, Rundheit und Oberflächenrauheit) mittels der sogenannten Grey Relational Analyse optimiert. Die Effekte der Bohrparameter und deren Wechselwirkungen auf den Bohrlochdurchmesser, Rundheit und Oberflächenrauheit wurden bestimmt. Die Analyse nach dem Taguchi und ANOVA Verfahren deutet darauf hin, dass der Einfluss des Bohrwerkstoffes auf die Oberflächenrauheit des gebohrten Loches hoch ist, dass aber der Einfluss auf den Lochdurchmesser und die Rundheit gering ist. Darüber hinaus ergaben die Ergebnisse der Grey Relational Analysis, dass die optimale Kombination der Bohrparameter (0,3 mm/U Zufuhrrate, Carbidwerkzeug und 3000 U/min Spindelgeschwindigkeit) eingesetzt werden kann, um einen minimalen diametralen Fehler, Rundheitsabweichung und Oberflächenrauheit zu erhalten.

Dr. Yunus Kayır is assistant professor in the department of Manufacturing Engineering at the Technology Faculty of the Gazi University in Ankara, Turkey. He obtained his PhD degree from Institute of Science and Technology of Gazi University in CAD/CAM. His research areas include machinability, cutting forces, and CAD/CAM.

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Published Online: 2014-10-01

Published in Print: 2014-01-02

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https://doi.org/10.3139/120.110523