Scholarlink

<p>This study presents a comprehensive comparative investigation of cutting force behavior during three hole-making techniques include, continuous drilling (CD), peck drilling (PD), and helical milling (HM) of medium-carbon steel AISI 1045. The investigation combines experimental measurements, analytical evaluation, and statistical optimization to provide an integrated understanding of each process performance. Experiments were executed under different machining parameters (spindle speeds, feed rates, and cutting fluid usage) based on Design of Experiments concept. In particular, the axial cutting force (F<sub>z</sub>) was measured using a custom-designed three-component dynamometer. To validate the experimental findings, finite element modeling (FEM) of the drilling process was performed. Statistical optimization was applied using Taguchi design, Grey Relational Analysis, Response Surface Methodology, and Genetic Algorithm (GRGA) approaches to determine the optimal hole making technique and the corresponding process parameters. Results revealed that HM produced the lowest cutting force compared to continuous and peck drilling. The FEM simulations exhibited agreement with experimental data, confirming the accuracy of the developed analytical model. According to the hybrid GRGA, the optimal GRG-F<sub>z</sub> values for CD, HM, and PD process are 0.99239, 0.95223, and 0.99414, respectively, at at N = 4000&#xa0;rpm and s = 50&#xa0;mm/min.</p> Graphical abstract <p></p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Modelling and optimization of cutting force in hole-making processes of AISI 1045 steel using Taguchi, GRA, and genetic algorithm techniques

  • 期刊论文

  • 发表日期：

    2026年7月20日

查看全文
  • Yasmine El-Taybany,
  • Hanan Kouta,
  • Samar El-Sanabary

摘要

This study presents a comprehensive comparative investigation of cutting force behavior during three hole-making techniques include, continuous drilling (CD), peck drilling (PD), and helical milling (HM) of medium-carbon steel AISI 1045. The investigation combines experimental measurements, analytical evaluation, and statistical optimization to provide an integrated understanding of each process performance. Experiments were executed under different machining parameters (spindle speeds, feed rates, and cutting fluid usage) based on Design of Experiments concept. In particular, the axial cutting force (Fz) was measured using a custom-designed three-component dynamometer. To validate the experimental findings, finite element modeling (FEM) of the drilling process was performed. Statistical optimization was applied using Taguchi design, Grey Relational Analysis, Response Surface Methodology, and Genetic Algorithm (GRGA) approaches to determine the optimal hole making technique and the corresponding process parameters. Results revealed that HM produced the lowest cutting force compared to continuous and peck drilling. The FEM simulations exhibited agreement with experimental data, confirming the accuracy of the developed analytical model. According to the hybrid GRGA, the optimal GRG-Fz values for CD, HM, and PD process are 0.99239, 0.95223, and 0.99414, respectively, at at N = 4000 rpm and s = 50 mm/min.

Graphical abstract