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Measurement
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a r t i c l e i n f o a b s t r a c t
Article history: In this study, the optimization of the cutting parameters on drill bit temperature in drilling
Received 5 February 2013 was performed. Al 7075 work piece and the uncoated and FirexÒ coated carbide drills in the
Received in revised form 7 May 2013 experimental were used. The optimization of the cutting parameters was evaluated by
Accepted 25 June 2013
Taguchi method. The control factors were considered as the cutting speed, feed rate and
Available online 3 July 2013
cutting tool. Taguchi method was used to determining the settings of cutting parameters.
The L18 orthogonal array was used in experimental planning. The most significant control
Keywords:
factors affected on drill bit temperature measurements was obtained by using analysis of
Taguchi method
Regression analysis
variance (ANOVA). Taguchi design method exhibit a good performance in the optimization
ANOVA of cutting parameters on drill bit temperature measurements. In addition, the empirical
Drill bit temperature equations of drill bit temperatures were derived by using regression analysis. The obtained
Drilling equations results compared with the drill bit temperature measurement results. The
empirical equations results indicated a good agreement with experimental results.
Ó 2013 Elsevier Ltd. All rights reserved.
0263-2241/$ - see front matter Ó 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.measurement.2013.06.046
3526 R. Çakıroğlu, A. Acır / Measurement 46 (2013) 3525–3531
Nomenclature
2. Materials and method Fig. 2. The twist drilling tool and thermocouple inserted through the hole
of internal coolant carbide drill [18].
2.1. Materials, measurement and drilling test conditions
The experimental setup for measuring the temperatures experiments was 200° to 1200° with ±0.05% measure-
during drilling was shown in Figs. 1 and 2. The drilling ment accuracy and its response time was 10 ls. The fixed
experiments were performed in dry conditions on Johnford drill and rotated workpiece (specimen) application was
CNC vertical milling using uncoated and FirexÒ coated car- used in the experiments. As shown in Fig. 2, the thermo-
bide twist drilling tools. FirexÒ product was a multi-layer couples was inserted through the coolant hole inside of
coating that combines TiN, TiAlN, and TiCN. The point an- the drills and the thermocouple used through the coolant
gle of a twist drill is 140° and drill diameter was 14 mm. hole was fixed near to the drill bit surface. The drilling tests
As test specimen material in drilling process, the Al 7075 were performed at the different drill types (uncoated and
alloy bar was used with 25 mm in diameter and 25 mm FirexÒ coated), cutting speed and feed rates. The drilling
in length. The spectrum analysis of Al 7075 alloy used in tests were done through work piece. The cutting parameter
the experiments was given in Table 1. Drill bit temperature levels used the design experiment based on Taguchi meth-
measurements in these experiments were used K type od for Al 7075 alloy drilling tests were given as shown in
thermocouples with a diameter of 1 mm. Measurement Table 2.
ranges K type (NiCr–Ni) thermocouples used in these
2.2. Taguchi method
Table 1
Chemical composition of the workpiece material (Al 7075) (% weight).
Si Fe Cu Mn Mg Cr Zn Ti Al
0.257 0.397 3.392 0.653 0.446 0.099 0.002 0.012 94.71
Workpiece
Thermocouple Dynamometer
wire Drill
Table 2
Assignment of the levels to the factors.
Machine Table 1 2 3
A Tool Uncoated Coated –
B Feed rate, f (mm/rev) 0.1 0.2 0.3
Fig. 1. CNC vertical milling machine and measurement method used in C Cutting Speed, Vc (m/min) 170 200 230
the experimental study [18].
R. Çakıroğlu, A. Acır / Measurement 46 (2013) 3525–3531 3527
Eq. (1) and the experimental results obtained for drill bit
Run experiments
temperature were illustrated in Table 4. The S/N analysis
ofthesignif icantfactor
was based on the experimental data.
Analyze data
Table 4
Table 3 Experimental results and S/N ratio, (g), for drill bit temperature.
Experimental design using L18 orthogonal array.
Exp. Tools Feed Cutting Temperature S/N (dB)
Experiment No. A (Tool) B (Feed rate) C (Cutting speed) No. rate speed (°C)
Table 5 Table 6
Results of ANOVA for drill bit temperature. S/N response table (g) for drill bit temperature (smaller is better).
DoF: degrees of freedom; SS: sequential sum of squares; MS: mean sum of
squares.
Table 7
Results of confirmation tests for drill bit temperature.
where SSA is the sum of squares for parameter A, V e is the
Initial cutting Optimal cutting
variance of error, tA is the degrees of freedom of parameter parameters parameters
A, and SST is the total sum of squares [17]. The PCR of the
Prediction Experimental
cutting parameters on the drill bit temperature were
shown in Table 5. ANOVA analysis is performed for a 5% Level A2B2C2 A2B3C1 A2B3C1
Temperature, (°C) 148 108.889 128
(P < 0.05) significance level, i.e., for a 95% confidence level S/N ratio (dB) 43.4052 41.2007 42.1441
to identify the cutting parameters that affect the drill bit Improvement of 1.2611 dB
temperature. Statistically, F-tests provided a decision at S/N ratio
some confidence level that is the realized significance lev- Prediction error 0.9434
(dB)
els, for each source of variation as shown in Tables 5. The F-
test and P value illustrated that the variation of the process
parameter made a big change on the performance charac- situation. In addition, the largest S/N ratio would be the
teristics [12–14]. According to Table 5, feed rates were ideal situation and the optimum cutting conditions was
found to be the major factor affecting the drill bit temper- determined by the level average responses from the S/N
atures (PCR: 56.15%) whereas, cutting speeds were found ratio for drill bit temperatures. The analysis was done by
to be the second important factor (PCR: 8.80%). But, a tool the S/N ratio at each level of each factor. The obtained
type shows a little effect on the drill bit temperature. As a analysis results were plotted in an S/N response graphical
result, feed rates of the drill bit temperature are found as form for drill bit temperatures. As seeing in a graphical
the most effective parameters. In addition, it can be seen forms (see Fig 4), the optimum conditions corresponds to
that the residual error containing all the major parameters cutting parameter level were shown as the peak point. In
from ANOVA results was 30% as shown in Table 5. addition, S/N response table were given in Table 6 for each
level of the cutting parameters as the mean S/N ratio. The
3.2. Determination of the optimum drilling conditions effects of all three control factors with levels derived from
Table 6 were shown in Fig. 4. The comparison of the pre-
The effect of each factor at different levels can be deter- dicted drill bit temperature with the actual drill bit tem-
mined by averaging the S/N ratios in the experiments. In perature using the optimal cutting parameters were
this study, it is the-smaller-the-better case, which means illustrated in Table 7. The improvement in S/N ratio from
the smallest drill bit temperature would be the ideal the initial cutting parameters to the level of optimal cut-
Mean of S/N ratios, dB
225 225
Temperature (°C)
Temperature (°C)
175 175
125 125
75 75
0,1 0,2 0,3 170 200 230
f, mm/rev Vc, m/min
ting parameters was 1.2611 dB. The values of drill bit 3.3. Correlation
temperature between initial and experimental cutting
parameters were decreased by 1.15 times. Therefore, the The correlations between the feed rate and cutting
values of drill bit temperature were greatly improved by speed and the measured cutting temperature were ob-
using the Taguchi approach. In addition, the optimal tained by regression analysis. The drill bit temperature
combination of levels for the criteria of the lowest equations obtained with regression analysis using MINI-
response and lowest S/N ratio were determined as TAB 14 software were as follows:
A2B3C1 for the ideal drill bit temperature as presented Uncoated drill bit temperature (°C):
in Table 7. The coated tool at level 2, the feed rate at level
T ð CÞ ¼ 93 203 f þ 0:833 V þ 1:33 f V ð3Þ
3 and the cutting speed at level 1 on cutting parameters
provided the best results for optimum drilling conditions Coated drill bit temperature (°C):
as regards drill bit temperature.
T ð CÞ ¼ 55 þ 151 f þ 0:594 V 1:42 f V ð4Þ
175 175
Temperature (°C)
Temperature (°C)
125 125
75 75
0,1 0,2 0,3 170 200 230
f, mm/rev Vc, m/min
Temperature (°C)
250
200
3.4. Confirmation test
150
100
The drill bit temperature is very important factor in the 50
tool wear, surface quality and cost. As shown in Figs. 5 and 0
6, the drill bit temperatures were given for different cut- 1 2 3 4 5 6 7 8 9
ting speeds and feed rates. Drill bit temperatures increased Experimental number
with increasing cutting speed whereas, the temperatures
decreased with increasing feed rates. Increasing feed rate Fig. 9. Comparison of experimental and predicted temperature values for
uncoated drill tools.
and decreasing cutting speed led to higher chip removal
rate. The heat energy occurred from friction in the drill–
chip contact interface was carried away with increasing
Experimental RA Training RA Testing
feed rate. Therefore, increasing feed rate and decreasing
200
cutting speed led to a decrease in drill bit temperature
Temperature (°C)
175
the along the drill–chip interface due to higher chip re-
moval rate. In addition, tool coating will not change the 150
drill bit temperature directly but alters the friction in the 125
drill–chip contact. The most important parameter for 100
change the drill bit temperature is a different thermal con- 75
ductivity between with and without coating. 1 2 3 4 5 6 7 8 9
In confirmation tests, the obtained experimental drill Experimental number
bit temperature values were divided into two parts and
these parts constitute training and testing data in this Fig. 10. Comparison of experimental and predicted temperature values
for coated drill tools.
study. The experimental data set consists of 9 values for
both uncoated and coated drills. Total experimental num-
ber is 18. The 7 values are used for training of the RA A comparison of prediction results with experimental tem-
whereas, the 2 values is performed for testing of the RA. perature results were shown in Figs. 7 and 8 for uncoated
The empirical Eqs. (3), (4) using the training data for the and coated cutting tools. Both training data and testing
prediction of drill bit temperature by RA was obtained. data were compared in this figure. The predicted tempera-
On the other hand, the testing data for in the confirmation ture values obtained with empirical Eqs. (3), (4) for both
tests with obtained empirical Eqs. (3), (4) were performed. training data and testing data values were very close to
corresponding experimental results as shown in Figs. 7
and 8. The obtained results of both experiment and models
show the small deviation less. As seen clearly from Figs. 7
and 8, the obtained RA models were illustrated as a feasible
and an effective way for the prediction of drill bit temper-
ature in drilling process. The R2 in testing data for temper-
ature prediction in the RA model is computed as 0.9799
and 0.9044 for coated and uncoated drills, respectively.
As a result, the empirical equations results obtained from
RA were indicated a good agreement with experimental re-
sults. In addition, the experimental results and obtained
Fig. 7. Comparison of regression model results with experimental results drill bit temperature with RA models are also plotted in
for drill bit temperature with FirexÒ coated carbide drill.
Figs. 9 and 10, as comparatively for both training data
and testing data. Except some small shifts from the center
line the dots form almost a straight line in all the plots. As a
result of the graphs the presented models fit the data well.
4. Conclusions
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