Quantitative Analysis of Frictional Forces and their Impact on Drilling Efficiency in Aluminum Alloy Machining

This study examines the intricate dynamics of friction and emphasizes how crucial it is to global energy use. Inspired by a 1493 discovery of Leonardo da Vinci, the study establishes the independence of friction force from contact area and highlights the significance of the friction coefficient as a load-related metric. The mechanical and chemical characteristics of aluminum alloys are discussed in this article along with an assessment of how well high-speed steel (HSS) drill bits work in drilling operations. Samples of aluminum are thoroughly analyzed for characteristics like yield stress, ultimate tensile strength, and elongation. The results show that aluminum makes up the majority of the sample, with trace elements like silicon and magnesium. At the same time, characteristics including Young’s modulus, thermal conductivity, and specific heat capacity are investigated for HSS drill bits, which are renowned for their durability and thermal resistance. To quantify thrust force and torque, experimental methods use a drill dynamometer built into a vertical drilling machine. Drill bits with different diameters (6 mm, 8 mm, and 12 mm) are evaluated at controlled feed rates and speeds. Accurate cutting force recording is ensured by real-time sensor data. The application of Finite Element Analysis (FEA) provides insights into how to optimize drilling processes for increased productivity and tool longevity by examining the stress distribution and deformation in drill bits under various operating situations.