ABSTRACT The study concerned with optimization of modulation-assisted drilling (MAD) operation for a difficult-to-cut material Ti6Al4 V was carried out via response surface method (RSM). Conventional drilling (CD) has been explored for comparison purposes. Experiments have been designed according to the Central Composite Design (CCD). The impact of machining input parameters on surface roughness (SR), machining power consumption, and tool wear (TW) was investigated for both cases. Pilot experiments were carried out to find out the best modulation range. Further drilling experiments were carried out varying feed rate, spindle speed, and tool diameter. Multiple regression analysis using RSM established relationships between these parameters and responses. ANOVA was used to develop and test the mathematical models. The models were effective in predicting the responses for MAD of Ti6Al4 V. The optimum drilling parameters are a tool diameter (TD) of 2 mm, feed rate (FR) of 0.030 mm/rev and spindle speed (SS) of 2176.87 rpm. SEM and EDS analyzes were performed to investigate the machined surfaces. From the study, it can be concluded that MAD is a promising machining process for difficult-to-cut materials with comparatively less thrust force, surface roughness and tool wear. Abbreviations SD Standard deviation; SS: Spindle Speed; TF: Thrust Force; BUE: Built-Up-Edge; PRESS: Prediction error sum of squares; TD: Tool Diameter; CD: Conventional Drilling; CV: Coefficient of variance; MAD: Modulation-Assisted Drilling; SR: Surface Roughness; VAM: Vibration-Assisted Machining; TW: Tool Wear; RSM: Response Surface Methodology; ANOVA: Analysis of Variance; FR: Feed Rate; SNR: Signal-to-Noise Ratio; FW: Flank wear

中文翻译：

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Ti-6Al-4V航空合金调制辅助钻孔响应面法优化

摘要 通过响应面法 (RSM) 对难切削材料 Ti6Al4 V 进行了有关调制辅助钻孔 (MAD) 操作优化的研究。出于比较的目的，已经探索了常规钻孔（CD）。实验是根据中央复合设计（CCD）设计的。针对这两种情况，研究了加工输入参数对表面粗糙度 (SR)、加工功耗和刀具磨损 (TW) 的影响。进行了试点实验以找出最佳调制范围。进一步的钻孔实验在不同的进给速率、主轴速度和刀具直径下进行。使用 RSM 的多元回归分析建立了这些参数和响应之间的关系。方差分析用于开发和测试数学模型。该模型可有效预测 Ti6Al4 V 的 MAD 响应。最佳钻孔参数是刀具直径 (TD) 为 2 mm，进给速率 (FR) 为 0.030 mm/rev 和主轴转速 (SS) 为 2176.87 rpm。进行SEM和EDS分析以研究加工表面。从研究中可以得出结论，对于推力、表面粗糙度和刀具磨损相对较小的难切削材料，MAD 是一种很有前途的加工工艺。缩写 SD 标准偏差；SS：主轴转速；TF：推力；BUE：内置边缘；PRESS：预测误差平方和；TD：刀具直径；CD：常规钻孔；CV：方差系数；MAD：调制辅助钻井；SR：表面粗糙度；VAM：振动辅助加工；TW：刀具磨损；RSM：响应面方法；方差分析：方差分析；法国：进给率；SNR：信噪比；FW：侧面磨损