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DOI 10.1007/s00170-007-0981-4
ORIGINAL ARTICLE
Received: 12 December 2006 / Accepted: 12 February 2007 / Published online: 10 March 2007
# Springer-Verlag London Limited 2007
1 Introduction
Metal matrix composites (MMC) are materials which
combine tough metallic matrix with a hard ceramic
reinforcement with superior properties like high strength
to wear ratio, high modulus, superior wear resistance and
corrosion resistance. These materials are widely used in
various fields like aerospace, automotive, electronics and
metallic industries and are very difficult to machine
material due to the presence of hard ceramic particle [15].
Most of the researches on the machining of Al/SiC
MMC have focused on turning and facing while drilling has
received less attention. Davim [1] investigated the study of
drilling metal matrix composites of type A356/20% SiC-T6
based on the Taguchi technique with the objective of
establishing the correlations between cutting velocity, feed
rate and cutting time with the evaluation of tool wear, the
specific cutting pressure and the hole surface roughness
using PCD drill. Tosun et al. [2, 3] investigated the effect of
the various cutting parameters on the surface quality and
microstructure on drilling of Al/17% SiC particulate MMC
by using various drills. They have suggested that TiN
coated HSS drills can be used for drilling Al/SiC-MMC
rather than solid carbide tools. The quality of the drilled
part is greatly influenced by the cutting conditions, tool
geometry, tool material, machining process, chip formation,
work piece material, tool wear, vibration during cutting, etc.
Thus in material removal processes, improper selection of
cutting conditions will result in rough surfaces [6].
Moreover, it is necessary to optimize the cutting parameters
to obtain an extended tool life and better productivity,
which are influenced by cutting force and torque [7].
Bhattacharyya [8] used the Lagrangian function method
in searching for optimum cutting parameters. Ermer [9]
used the geometric programming method. Lin [10] inves-
251
cutting point angles (90, 115 and 140 degrees), coated by TiN
are used throughout the experimental work.
The average surface roughness (Ra), cutting force (Fc)
and torque (T) are considered as responses for this study. The
surface roughness is measured at three positions spaced at
120 intervals around the hole circumference. The surface
roughness of each hole is taken as the mean of three
circumferential readings. The cutting force and torque for
each trial is measured by using strain gauge dynamometer.
2.2 Plan of investigation
The factors and their levels considered in this study are
shown in Table 1. Experiments are conducted with three
factors each at three levels and hence a three level
orthogonal array (OA) is chosen. Degrees of freedom
(Dof) required for the design are six. The OA, which
satisfies the required Dof is L9. The experiments are
conducted using L9 OA and the response values obtained
are given in Table 2.
X
1 n 1
n i1 y2ij
2 Experimental works
n
1X
y2
n i1 ij
!
2
Unit
m/min
mm/rev
degree
Levels
1
35.18
0.050
90
56.54
0.125
115
87.96
0.20
140
252
1
2
3
4
5
6
7
8
9
1
1
1
2
2
2
3
3
3
1
2
3
1
2
3
1
2
3
PA
Responses
1
2
3
2
3
1
3
1
2
Ra in m
Fc in N
T in Nm
7.83
4.01
2.22
6.70
5.80
6.09
6.01
8.27
6.20
107.87
254.96
470.67
186.31
539.33
1186.53
274.57
1078.66
1274.78
0.88
2.06
2.26
1.96
1.28
3.24
0.69
2.55
2.16
Where
2
2
3
y1y2y3:::::::yn
n
P
yiy2
(To be used for S/N ratio with Larger the better manner)
max yij ; i 1; 2; :::::n yij
Zij
max yij ; i 1; 2; ::::::n min yij ; i 1; 2; :::::n
n1
5
(To be used for S/N ratio with smaller the better manner)
yij Target min yij Target; i 1; 2; ::::::n
Zij
max yij Target; i 1; 2; :::::n min yij Target; i 1; 2; ::::::n
(To be used for S/N ratio with nominal the best manner)
Step 3 Calculate the grey relational co-efficient for the
normalized S/N ratio values.
yo k ; yi k
min max
oj k max
where
1. j=1,2...n; k=1,2...m, n is the number of experimental
data items and m is the number of responses.
2. yo(k) is the reference sequence (yo(k)=1, k=1,2...m);
yj(k) is the specific comparison
sequence.
3. oj yo k yj k The absolute value of the
difference between
yo(k) and yj(k)
4. min min minyo k yj k is the smallest value
8j2i 8k
of yj(k)
5. max max maxyo k yj k is the largest value
8j2i 8k
of yj(k)
m
1X
g
k i1 ij
253
m Average SN ratio
b
m
q
X
i m
i1
11
1
2
3
4
5
6
7
8
9
S/N ratios
Ra
Fc
Ra
Fc
17.875
12.063
6.927
16.521
15.269
15.692
15.577
18.350
15.848
40.658
48.129
53.454
45.405
54.637
61.486
48.773
60.658
62.109
1.110
6.277
7.082
5.845
2.144
10.211
3.223
8.131
6.689
0.958
0.450
0.000
0.840
0.730
0.767
0.757
1.000
0.781
0.000
0.348
0.597
0.221
0.652
0.971
0.378
0.932
1.000
0.157
0.707
0.767
0.675
0.400
1.000
0.000
0.845
0.738
254
1
2
3
4
5
6
7
8
9
Grey grade
Ra
Fc
0.923
0.476
0.333
0.757
0.650
0.682
0.673
1.000
0.695
0.333
0.434
0.553
0.391
0.589
0.945
0.446
0.881
1.000
0.372
0.631
0.682
0.606
0.454
1.000
0.333
0.764
0.656
0.543
0.514
0.523
0.585
0.564
0.876
0.484
0.881
0.784
neff
Total number
of observations
0
1
5 Confirmation experiment
The confirmation experiment is conducted at the optimum
settings to verify the quality characteristics for drilling of
Al/SiC MMC composite by drilling process recommended
by the investigation. The response values by the confirmation experiment trial at the optimal settings are Ra=7.6m,
Fc=1765.08 N and T=3.16 Nm. The grey relational grade
(cgg) value as per above discussion is found to be 0.952.
This result is within the 95% confidence interval of the
predicted optimum condition and also grey grade value of
Table 6 Results of ANOVA on grey grade
Factor
Dof
Sum of
squares
Mean
squares
FTest
%
Contribution
V
F
PA
Error
Total
2
2
2
2
8
0.059
0.054
0.089
0.004
0.206
0.030
0.027
0.045
0.002
0.026
15.00
13.50
22.50
28.64
26.21
43.21
1.94
100
Cutting speed
Feed
Point angle
0.527
0.537
0.767
0.675
0.653
0.627
0.716
0.728
0.524
6 Conclusions
Drilling experiments were conducted on a radial drilling
machine with TiN coated HSS twist drill and Al/SiC 10%
by volume fraction metal matrix composites as work
material. The surface roughness, cutting force and torque
values were collected under different cutting conditions for
various combinations of drilling parameters. The following
conclusions were drawn.
255
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