Abstract

In the pursuit of meeting the exacting demands of the aerospace industry, precision and efficiency in machining processes are paramount. This research delves into the intricacies of micro boring, a critical machining operation, with the aim of optimizing its parameters to elevate machining accuracy and efficiency. The study focuses on aerospace materials, particularly titanium alloys and composites, to address the unique challenges posed by their high strength and lightweight characteristics. This study focuses on micro boring, an essential machining operation, with the objective of minimizing thrust forces, circularity errors, and reducing burr size in the micro boring process on a PMMA (Poly methyl methacrylate) work piece measuring piece of 95*30*4mm. The Design of Experiment (DOE) methodology, coupled with Gray Relational Analysis, is employed to achieve these objectives. Two controllable parameters, namely, cutting speed and feed rate, are considered for optimization with respect to thrust forces, circularity, and burr size. A set of experiments is designed using the DOE technique, where each parameter is varied at three different levels. The machining is performed using a High-Speed Steel (HSS) drill bit with a diameter of 1.5mm based on the generated run order. The analysis reveals that a combination of high cutting speed and low feed rate yields superior results, exhibiting reduced circularity error and smaller burr size. This finding highlights the significance of the selected parameters in influencing the micro boring process on PMMA materials. The identified optimal conditions, specifically high cutting speed and low feed rate, contribute to minimizing thrust forces, circularity errors, and burr size, thereby enhancing the overall micro boring process in this particular material.

Description