Assessment of Hole Quality, Thermal Analysis, and Chip Formation during Dry Drilling Process of Gray Cast Iron ASTM A48
Abstract
:1. Introduction
2. Materials and Methods
2.1. Workpiece Material
2.2. Machine Setup, Cutting Parameters, and Cutting Tool
2.3. Measurement of Temperature
2.4. Post-Drilling Experiments
2.5. Analysis of Variance
3. Results and Discussions
3.1. Thermal Analysis
3.2. Assessment of Hole Quality
3.2.1. Surface Roughness
3.2.2. Hole Size
3.2.3. Circularity
3.3. Chip Morphology
4. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Properties | Value |
---|---|
Density (g/cm3) | 7.15 |
Hardness (BHN) | 174–210 |
Ultimate tensile strength (MPa) | 207 |
Melting temperature (F) | 2050–2120 |
Element | Composition |
---|---|
Carbon | 3.1–3.3 |
Sulfur | 0.05–0.12 |
Phosphorus | 0.02–0.1 |
Silicon | 2.1–2.3 |
Manganese | 0.5–0.9 |
Levels | Feed Rate (m/min) | Spindle Speed (n) | Cutting Speed (Vc) |
---|---|---|---|
rpm | m/min | ||
1 | 0.013 | 43 | 1.35 |
2 | 0.025 | 77 | 2.42 |
3 | 0.034 | 141 | 4.43 |
4 | 0.049 | 308 | 9.67 |
Drill Bit Material | Description |
---|---|
Material | High-speed steel |
Diameter | 10 mm |
Point angle | 118° |
Helix angle | 30° |
Source | DF | Seq SS | Contribution | Adj S.S. | Adj MS | F-Value | p-Value |
---|---|---|---|---|---|---|---|
Model | 6 | 119,206 | 98.59% | 119,206 | 19,867.7 | 105.07 | 0.000 |
Linear | 6 | 119,206 | 98.59% | 119,206 | 19,867.7 | 105.07 | 0.000 |
Spindle speed | 3 | 67,999 | 56.24% | 67,999 | 22,666.3 | 119.87 | 0.000 |
Feed rate | 3 | 51,207 | 42.35% | 51,207 | 17,069.1 | 90.27 | 0.000 |
Error | 9 | 1702 | 1.41% | 1702 | 189.1 | - | - |
Total | 15 | 120,908 | 100.00% | - | - | - | - |
Source | DF | Seq SS | Contribution | Adj SS | Adj MS | F-Value | p-Value |
---|---|---|---|---|---|---|---|
Model | 6 | 4.46877 | 99.12% | 4.46877 | 0.744794 | 168.57 | 0.000 |
Linear | 6 | 4.46877 | 99.12% | 4.46877 | 0.744794 | 168.57 | 0.000 |
Spindle speed | 3 | 1.98912 | 44.12% | 1.98912 | 0.663042 | 150.06 | 0.000 |
Feed rate | 3 | 2.47964 | 55.00% | 2.47964 | 0.826547 | 187.07 | 0.000 |
Error | 9 | 0.03977 | 0.88% | 0.03977 | 0.004418 | - | - |
Total | 15 | 4.50853 | 100.00% | - | - | - | - |
Source | DF | Seq SS | Contribution | Adj SS | Adj MS | F-Value | p-Value |
---|---|---|---|---|---|---|---|
Model | 6 | 0.021121 | 95.54% | 0.021121 | 0.00704 | 64.32 | 0.001 |
Linear | 6 | 0.021121 | 95.54% | 0.021121 | 0.00704 | 64.32 | 0.001 |
Spindle speed | 3 | 0.004722 | 21.36% | 0.004722 | 0.001574 | 14.38 | 0.001 |
Feed rate | 3 | 0.016399 | 74.18% | 0.016399 | 0.005466 | 49.94 | 0.000 |
Error | 9 | 0.000985 | 4.46% | 0.000985 | 0.000109 | - | - |
Total | 15 | 0.022105 | 100.00% | - | - | - | - |
Circularity | |||||||
---|---|---|---|---|---|---|---|
Source | DF | Seq SS | Contribution | Adj SS | Adj MS | F-Value | p-Value |
Model | 6 | 0.0000148 | 95.08% | 0.0000148 | 0.00005 | 57.79 | 0.001 |
Linear | 6 | 0.0000148 | 95.08% | 0.0000148 | 0.00005 | 57.79 | 0.001 |
Spindle speed | 3 | 0.000038 | 24.26% | 0.000038 | 0.000013 | 14.79 | 0.001 |
Feed rate | 3 | 0.000110 | 70.82% | 0.000110 | 0.000037 | 43.17 | 0.000 |
Error | 9 | 0.000008 | 4.92% | 0.000008 | 0.000001 | - | - |
Total | 15 | 0.000155 | 100.00% | - | - | - | - |
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Habib, N.; Sharif, A.; Hussain, A.; Aamir, M.; Giasin, K.; Pimenov, D.Y. Assessment of Hole Quality, Thermal Analysis, and Chip Formation during Dry Drilling Process of Gray Cast Iron ASTM A48. Eng 2022, 3, 301-310. https://doi.org/10.3390/eng3030022
Habib N, Sharif A, Hussain A, Aamir M, Giasin K, Pimenov DY. Assessment of Hole Quality, Thermal Analysis, and Chip Formation during Dry Drilling Process of Gray Cast Iron ASTM A48. Eng. 2022; 3(3):301-310. https://doi.org/10.3390/eng3030022
Chicago/Turabian StyleHabib, Numan, Aamer Sharif, Aqib Hussain, Muhammad Aamir, Khaled Giasin, and Danil Yurievich Pimenov. 2022. "Assessment of Hole Quality, Thermal Analysis, and Chip Formation during Dry Drilling Process of Gray Cast Iron ASTM A48" Eng 3, no. 3: 301-310. https://doi.org/10.3390/eng3030022