International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974

Research Paper
EFFECT OF DRILLING PARAMETERS ON SURFACE
ROUGHNESS, TOOL WEAR, MATERIAL REMOVAL RATE
AND HOLE DIAMETER ERROR IN DRILLING OF OHNS
J.Pradeep Kumar1*, P.Packiaraj2
Address for Correspondence
1*
Assistant Professor, 2 PG Student, Department of Production Engineering PSG College of Technology
Coimbatore, INDIA
ABSTRACT
The aim of this work is to utilize taguchi method to investigate the effects of drilling parameters such as cutting speed (5,
6.5, 8 m/min), feed (0.15, 0.20, 0.25mm/rev) and drill tool diameter (10, 12, 15mm) on surface roughness, tool wear by
weight, material removal rate and hole diameter error in drilling of OHNS material using HSS spiral drill. Orthogonal arrays
of taguchi, the Signal–to- Noise (S/N) ratio, the analysis of variance (ANOVA), and regression analysis are employed to
analyze the effect of drilling parameters on the quality of drilled holes. A series of experiments based on L18 orthogonal
array are conducted using DECKEL MAHO-DMC 835V machining center .The experimental results are collected and
analyzed using commercial software package MINITAB 13. Linear regression equations are developed with an objective to
establish a correlation between the selected drilling parameters with the quality characteristics of the drilled holes. The
predicted values are compared with experimental data and are found to be in good agreement.
KEYWORDS: Drilling, OHNS, Taguchi method, Surface finish, Tool wear, Material removal rate, Hole diameter error,
Regression analysis, Analysis of variance.
1. INTRODUCTION davim.J et.al,2003) ,which are determined based on
The largest amount of money spent on any one class experience or by the use of a handbook (Graham T
of cutting tools is spent on drills. Therefore, from the et.al, 2008). In this context, three parameters speed,
viewpoint of cost and productivity, modeling and feed and drill tool diameter are selected as
optimization of drilling processes are extremely controllable parameters and parameters like surface
important for the manufacturing industry (S.A. Jalali roughness(Ra), MRR, tool wear by weight and hole
et.al 1991). Amongst traditional machining diameter error are considered as the required quality
processes, drilling is one of the most important metal characteristic responses. Several mathematical
cutting operations, comprising 33% of all metal models based on statistical regression and neural
cutting operations (Chen W C et.al, 1999). Although network techniques have been constructed to
modern metal cutting methods have tremendously establish the relationship between the cutting
improved in the manufacturing industry, performance and cutting parameters. Han-Ming
conventional drilling process still remains one of the Chow ct.al, 2008 has explored how different
most common processes. parameters such as drill shape, friction angle, friction
Taguchi design is proved to be an efficient tool to contact area ratio, feed rate, and drilling speed would
produce high quality products at very less cost. The affect the response parameter for austenite stainless
objective of taguchi robust design is to determine the steel (AISI 304) using taguchi method. Routio et.al,
optimal parameter settings and making the process 1995 studied the tool wear and failure in the drilling
performance insensitive to various sources of of stainless steels. J Paulo davim, 2003 presented a
variations. The approach can economically satisfy the study on the influence of cutting parameters such as
needs of the problem solving and design cutting velocity, feed rate, cutting time on drilling
optimization. Taguchi technique allows the process metal – matrix composites and concluded that
optimization with minimum number of experiments interaction of cutting speed/feed is the most
without need for process model development. Thus, important factor contributing towards surface
by this method, it is possible to reduce the time and roughness of drilled holes. C.C Tsao, 2004 performed
cost for experimental investigations and thus enhance an experimental work with an objective to establish a
the performance characteristics. correlation between feed rate, spindle speed and drill
The material chosen for the study is Oil hardened diameter with the induced delamination in a CFRP
Non Shrinking (OHNS) steel which comes under tool laminate. Mohan et.al, 2005 used taguchi method to
steel is widely used in manufacturing tools such as study the influence of process parameters such as
machine screw taps, threading dies, intricate press speed, feed rate, drill size, specimen thickness on
tools, chasers and milling cutters. The percentage of cutting force and torque during drilling of glass fiber
carbon and its alloys in OHNS steel are: Carbon polyester reinforced composites. Basavarajappa et.al,
0.95%, Chromium 0.5%, V 0.15%, W 0.6% and the 2008 discussed the influence of speed and feed on
rest is iron. Studying about machining of this steel drilling of hybrid metal matrix composites based on
using drilling process will be useful for taguchi techniques. Mustafa et.al 2009 performed an
manufacturing industries. experimental investigation in the optimization of
Drilling operation is evaluated based on the cutting parameters for surface roughness in dry
performance characteristics such as surface drilling process using taguchi method. It is evident
roughness, material removal rate (MRR), tool wear, from literature survey that there exists a need to study
tool life, cutting force, hole diameter error, power on the effects of various parameters on drilling of
consumption and are strongly correlated with the OHNS since lot of works are reported pertaining to
cutting parameters such as cutting speed, feed, depth drilling of composite materials, aluminum alloys and
of cut, and tool geometry (Chryssolouris G et.al, very rarely on drilling of tool steels.
1990, Chua MS et.al, 1993, Yang H et.al,1998, Paulo

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 International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974

2. Experimental works. roughness is an average taken from eight

In this study, the settings of drilling parameters were
determined by using taguchi experimental design
method. Orthogonal arrays of taguchi, the Signal – to
– Noise (S/N) ratio, the analysis of variance
(ANOVA), and regression analysis are employed to
analyze the effect of the drilling parameters on
surface roughness, tool wear by weight, material
removal rate (MRR) and hole diameter error values.
In order to reduce time and cost, experiments are
carried out using L18 orthogonal array. For the
purpose of observing the degree of influence of the
cutting conditions in drilling process three factors
(cutting speed, feed and drill diameter), each at three
levels are taken into account as shown in Table 1 and
2.
2.1 Experimental set up
Drilling tests are performed on DECKEL MAHO-
DMC 835V (continues speed up to 14000rpm and
14kw spindle power) CNC machining centre using
HSS spiral type drill bits. To guarantee the initial
conditions of each test, a new drill tool is used in
each experiment. The work piece is of OHNS
material with dimensions 300 x 100 x 10 mm. The
experimental setup is shown
Figure 1. Experimental setup
in figure 1.CNC part programs are created by
employing MasterCam 10 CAD/CAM software on a
personal computer. The mean surface roughness (Ra)
is measured with a Mitutoyo Surftest SJ-201 Series
178-portable surface roughness tester instrument. The hole diameter error and calculated values of material
cut –off and sampling lengths for each measurement
are taken as 0.8 and 5mm, respectively. The surface
Table 1. Process parameters and their levels
measurements along the holes. In these experiments,
the final shape of the hole is determined using a
Renishaw cyclone CMM. The measurement of hole
diameter is of critical importance for many
applications. One of the most important fundamental
factors for engineering components is precision
assembly. Hence, in this study, the hole diameter
error of a produced hole is measured using a
Renishaw cyclone CMM. The major system
components are the three-axis mechanical setup, the
probe head, control unit, and PC. The CMM used
here is a vertical-arm CMM, using a Renishaw PH
sensor mount with a touch-trigger probe. The
operating system utilized is Windows for PCs.
Figure 2. Set up for measuring Hole diameter
error
The setup used for measuring hole diameter error is
shown in figure 2 and the experimental results are
shown in table 2.The drill tool weight comparison
before and after machining is taken as a measure of
tool wears. The tool wear is measured using the
shimadzu electronic balance machine. The material
removal rate in drilling of OHNS plate has been
calculated by using the standard relation:
MRR= ( d2*f*N) mm3/min (1)
Where,
MRR= Material removal rate, d = diameter of the drill bit
in mm, f = feed in mm/rev, N = spindle speed in rev/min.
The measured values of surface roughness, tool wear,
removal rate are shown in Table 2.

Table 2. L18 orthogonal array and the desired parameter values

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 International Journal of Advanced Engineering Research and Studies
3. Analysis of experimental results and discussion
3.1 Regression Analysis
The cutting speed, feed and drill tool diamter are
considered in the development of mathematical
models for surface rougness, toolwear, metal removal
rate and hole diameter accuracy.The correlation
between the considered drilling paramters for drilling
conditions on OHNS are obtaine by linear regression.
The linear polynomial models are developed using
commercially available Minitab 13 software for
various drilling paramters and are listed as below:
Surface Roughness= 0.81+0.056A+25.6B-0.290C
(2)
Tool Wear= 3.05-0.0914A+3.47B-0.176C (3)
Material Removal Rate
= -7988+611A+19934B+326C (4)
Hole Diameter Error= - 0.0176 - 0.00109A + 0.112 B
+ 0.00265C (5)
Where:
A = Cutting speed (m/mm), B = Feed (mm/rev), C = Drill
diameter (mm).
The predicated or theoretical values of various
parameters obtained using regression equations are
shown in table 2. The predicted values are also
compared with experimental values and shown in
figure 3.
Figure 3. Comparison of experimental values and
predicted values
IJAERS/Vol. I/ Issue III/April-June, 2012/150-154
E-ISSN2249–8974
3.2 Analysis of S/N ratio
In the taguchi method, the term signal represents the
desirable value (mean) for the output characteristic
and the term noise represents the undesirable value
(deviation, SD) for the output characteristic.
Therefore the S/N ratio is the ratio of the mean to the
SD. Taguchi uses the S/N ratio to measure the quality
characteristic deviating form the desired value. There
are several S/N ratios available, depending on the
type of the characteristic; lower the better, nominal is
best and higher the better.(Phadke MS(1989), Philip J
Ross (1996). The lower the better characteristic
(Eq.6) is used for surface roughness, tool wear and
hole diameter error and higher the better (Eq.7) is
used for Metal removal rate and both the
characteristics are formulated as shown below
Smaller the Better :
S/NL= (6)
Higher the Better :
S/NH= (7)
Where , is the average of observed data, is the
variance of y, n is the number of observations and y
is the observed data. Using the above-presented data
with the selected above formula for calculating S/N,
the Taguchi experiment results are summarized in
Table 3,4,5,6 and presented in Fig. 4,5.6.7, which
were obtained by means of MINITAB 13 statistical
software. It can be noticed form the S/N responses
that feed is the most important factor affecting
surface roughness, tool wear, metal removal rate and
drill tool diameter is the most important factor
affecting the hole diameter accuracy. Fig 4,5,6,7
shows the effect of drilling parameters on surface
roughness, tool wear, metal removal rate and hole
diameter error respectively.
Table 3. Responses for Signal-to-Noise ratio (S/N)
– Surface Roughness
Table 4. Responses for Signal-to-Noise ratio (S/N)
– Tool Wear
Table 5. Responses for Signal-to-Noise ratio (S/N)
– Metal Removal Rate
Table 6. Responses for Signal-to-Noise ratio (S/N)
– Hole Diameter Error
 International Journal of Advanced Engineering Research and Studies
Fig 4. Main effect plot for Surface Roughness
Fig 5. Main effect plot for Tool Wear
Fig 6. Main effect plot for Material removal rate
Fig 7. Main effect plot for Hole dimater error
3.3 Analysis of variance (ANOVA)
The analysis of variance (ANOVA) establishes the
relative significance of factors in terms of their
percentage contribution to the response (Phadke,
1989; Ross, 1996) The ANOVA is also needed for
estimating the variance of error for the effects and the
confidence interval of the prediction error. The
analysis is performed on S/N ratios to obtain the
percentage contribution of each of the factors.
DoF: Degree of freedom, SS: Sum of squares, %c:
Percent contribution, #: 95% confidence interval
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E-ISSN2249–8974
From table 7, observation can be made such that the
feed (62.24%) have greater influence on surface
roughness and drill tool diameter, cutting speed
accounts 13.94%, 11.48% percent contribution
respectively on the holes surface roughness. From
table 8, observation can be made such that the feed
(53.93%) have greater influence on tool wear and,
cutting speed and drill tool diameter accounts
21.48%, 5.88% percent contribution respectively on
tool wear. From table 9, observation can be made
such that the feed (39.21%) have greater influence on
MRR and cutting speed and drill toll diameter
accounts 32.87%, 25.36% percent contribution
respectively on MRR. From table 10, observation can
be made such that the feed (83.38%) have greater
influence on hole diameter error and cutting speed
and drill toll diameter accounts 1.17%, 0.50% percent
contribution respectively on the hole diameter error.
4. CONCLUSIONS
This study has discussed an application of taguchi
method for investigating the effects of drilling
parameters on surface roughness, tool wear, material
removal rate and hole diameter error in drilling of
OHNS. From the analysis of results in the drilling
process using conceptual Signal-to-Noise(S/N) ratio
approach, regression analysis, analysis of
variance(ANOVA) the following can be concluded
from the present study:
• Statistically designed experiments based on
taguchi method are performed using L18
orthogonal array to analyze the effect of
drilling parameters on surface roughness, tool
wear, material removal rate and hole diameter
error.
• Linear regression equations are developed to
predict the values of surface roughness, tool
wear, material removal rate and hole diameter
error and the predicted values are compared
with measured values.
• Through ANOVA, it is found that the feed
and speed are important process parameters
to control surface roughness, tool wear,
material removal rate and hole diameter error.
• Thus it is essential to employ suitable
combination of cutting speed and feed so as
to reduce the variations that can affect the
quality of the holes that are drilled on OHNS
material.
• Further study could consider more factors
(drill properties [point angle, helix angle,
flute number, types of drills] and run out of
drill, thrust force, toques etc.) in the research
to see how these factors would affect the hole
quality.
ACKNOWLEDGEMENTS
The authors express their sincere thanks to the
Management, Principal - PSG College of
Technology, Dr.K.Prakasan – Professor and Head,
Department of Production Engineering, PSG College
of technology for providing necessary support and
infrastructure to carry out this work.
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