Influence Of Machining Parameters On Drilling Characteristics Of Al6061/Sic Mmcs: A Taguchi-Based Approach

Abstract

This research investigates the influence of machining parameters on the drilling characteristics of Al6061/SiC metal matrix composites (MMCs), which are increasingly employed in the aerospace and automotive sectors due to their exceptional mechanical and tribological properties. However, the presence of hard SiC particles complicates the drilling process, resulting in heightened thrust forces, tool wear, and surface imperfections. The study utilizes a Taguchi L9 orthogonal array to systematically assess the effects of four process parameters—spindle speed (800, 1200, 1600 rpm), feed rate (0.1, 0.2, 0.3 mm/rev), tool diameter (6, 8, 10 mm), and reinforcement percentage (5%, 10%, 15%)—on thrust force, material removal rate (MRR), and surface roughness. The experimental findings indicate that the feed rate is the most significant factor influencing all responses. An increase in feed rate from 0.1 to 0.3 mm/rev results in a thrust force increase of approximately 70%, from 200 N to over 340 N, and a rise in surface roughness (Ra) by about 0.012 μm, while MRR enhances by roughly 50%. In contrast, higher spindle speeds (from 800 to 1600 rpm) lead to a 35% reduction in thrust force and a decrease in surface roughness by 0.005 μm, attributed to thermal softening effects. Larger tool diameters (from 6 mm to 10 mm) significantly boost MRR but also increase cutting forces. ANOVA analysis reveals that the feed rate contributes to over 60% of the variation in thrust force and MRR, while the reinforcement percentage primarily influences surface roughness and thrust forces. The regression models correlate well with the experimental data, offering reliable predictions for process optimization. These findings underscore the necessity of balancing productivity and surface quality through optimized parameter settings, which is essential for enhancing MMC manufacturing efficiency.