Mathematical Modelling and Multiresponse Optimization to Minimize Surface Roughness in Drilling Custom 450 Stainless Steel

Abstract

In the present study, drilling tests were carried out on Custom 450 stainless steel workpieces. The influences of control factors (cutting speed-Vc, feed rate-f and drill bit geometry-D) on the drilled holes’ surface roughness (Ra) and on the size of adhering workpiece (AW) to the drill bit was examined. The results obtained from tests designed based on the Taguchi’s L16 orthogonal array were analysed using ANOVA and grey relational analyses (GRA). Therefore, the control factors and their levels were optimised simultaneously for the quality characteristics (Ra and AW). In addition, mathematical models were also developed using Response Surface Methodology (RSM) in order to estimate the quality characteristics. The used drill bits were examined under digital and scanning electron microscopes and EDX analysis was also carried out on the drill bits. The experimental results showed that the Ra and AW increased with increasing the f. It was also seen that increasing the Vc resulted in decrease in the size of adhering layer and that the drill bit wear became clear at the highest Vc of 60 m/min. According to the ANOVA results, the most effective control factor on Ra was f with 93.11% and Vc with 58.14% on AW. GRA analysis revealed that the most influential control factor was the f and that the optimum levels were 60 m/min Vc, 0.005 m/min f and drill bit 4.