Application of Response Surface Methodology to Optimize Cutting Process Parameters in Aluminum Silicon Alloy Drilling

Drilling is an essential step in the manufacturing process for virtually every sector of the economy. Despite this, drilling operations are notoriously tough due to the complicated geometry of the drill bit. In the context of traditional drilling techniques, the process of cutting is achieved through a synergistic interaction involving the chisel edge and multiple cutting lips. Upon conducting an examination of the cutting procedure, it is evident that the initial step involved in creating the chisel edge is to establish a hole at the twist drill's core. The edge of the chisel then creates a cut in an orthogonal direction, moving away from the center at a rake angle that is less than zero. Due to the inclusion of the radius in the equation, it is necessary to employ element formulation in order to conduct force analysis while analyzing the cutting action at the cutting lip. This is due to the oblique cutting action of the cutting lip. In the body of published research, drilling activities that were carried out and evaluated at a variety of inclination angles are quite rare. The purpose of this research is to look into the effects of various inclination angles, drilling conditions, and feed rates on the cutting performance of a drilling operation. According to the findings of the study, the amount of cutting force required for different degrees of inclination differs because of the different ways in which the tool and the workpiece come into contact with each other.