Experimental investigation to optimize tool performance in high-speed drilling: a comparative study

Abstract

In this study, the influence of drilling parameters on circularity error, tool tip temperature and flank wear is investigated while drilling of Ti–6Al–4V alloy specimens with dissimilar cutting tool materials under dry machining conditions. In addition, optimal control factors for circularity error, tool tip temperature and flank wear have been determined using Taguchi–Grey relational analysis. Rotational speed of the spindle, feed rate and drill bit material are considered as control factors. Numerous drilling experimental runs have been performed employing L27 orthogonal array on a CNC vertical machining centre with 12Ø-mm-diameter holes on 10-mm-thick plates. An infrared thermal camera FLIR E60 is employed to record the temperature at tool chip interface, and Kistler 8793 tri-axial accelerometer is used to get hold of vibration data in real time. Analysis of variance has been carried out to ascertain the most substantial control factors among rotational speed, feed rate and drill bit material and also to establish the effects of the same over circularity error (Cr), temperature (T) and flank wear (VB).