study of thrust force in drilling al / sic - nano tio2 metal ...using sem and afm in analyzing of...

Study of Thrust Force in Drilling Al / SiC - Nano TiO2

Metal Matrix Composites Using Response Surface Method

N. Prem kumar1*, N. Mani2 & K. Palanikumar2

1Research Scholar,

Department of Mechanical Engineering

Anna University, Sri Sai Ram Institute of Technology, India, [email protected]

2Department of Mechanical Engineering,

Sri Sai Ram Engineering College, India

Abstract

Drilling process is ultimate and prime route in component assembling. It should

give a good interlaminer property and dimensionally balanced. Due to imperfect

drilling, assembly of components is difficult and further leads to lower

performance. This paper discusses the outcome of drilling parameter such as drill

diameter, speed of spindle and feed rate produces thrust force on Al / SiC with

TiO2 Nano Composite. Thrust force is a predominant and inevitable parameter in

hole making operation. Titanium Nitride coated twist drill bit of 6, 8 and 10mm

diameters are used. TiN coated HSS twist drills showed the better performance

with reference to the thrust force. The current study deals with, employing Box-

Behnken design using response surface methology for optimizing the drilling

parameters on the Al6061-SiC/Nano TiO2 composite. The effectiveness of various

parameters against thrust force of Al6061-SiC/ Nano TiO2 composites has been

evaluated by surface plots and three-dimensional graphs. The result indicates that

thrust force is increases due to increasing of feed rate and drill diameter and

reduced by increasing the spindle speed. Further, investigation was performed by

using SEM and AFM in analyzing of the surface of drilled area of given composite.

Keywords: Drilling, Thrust force, SEM, EDAX, Titanium Nitride coated drill

bits, Al-SiC/TiO2 nano powder and Box–Behnken experimental design

1. Introduction

In Recent Trend, Metal Matrix Nano composites proves significant applications in

automotive, aero, chemical industries, structural application and diversional fields required

deep analysis of machined surface, which determine the material to overcome rigorous

condition of stress, high temperature, and corrosion. It gives good mechanical properties

such as hardness, density, tensile strength, electrical conductivity, thermal conductivity,

ductility and wear resistance. Matrix undergoes a small elastic strain which forms a

microcracks and growth of voids in the composites [DI ZHANG, KENJIRO SUGIO et al.

2008]. The flow of aluminum matrix (high temperature) embedded with reinforcement

materials, usually ceramic with equal dimension in all direction or an aspect ratio less than

4 [RAMULU M et al. 2002]. The presence of silicon carbide in the matrix material

Tierärztliche Praxis

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directly influences the behavior of the material in aspect of heat treatment and its allied

processes. Silicon carbide act as a driving force for the utilization of metal matrix

composites by its performance, low cost and environmental benefits [GAITONDE V N et

al. 2008]. The factor which affects the TiO2 during composite production are interfacial bonding and crystalline structure [TOSUN N et al. 2006]. Drilling characteristics of MMC

is distinct from the metal drilling, due to their anisotropic and inhomogeneous in nature.

PALANIKUMAR K et al. 2014 has investigated and analyzed the different cutting

parameter of hybrid MMC that concludes the thrust force is influenced by feed rate in

drilling operation. RAJMOHAN T et al. 2012 investigated by using hybrid metal matrix

composite appropriate model was developed for predicting the thrust force exerted through

drilling process. Different parameter for machining are analysed for thrust force by using

response surface method. RAMULU M et al. 2002 investigated on drilling characteristics

of (Al2O3) p/6061composite pertaining to drill force, tool wear, chip formation, quality of

drilled hole and PCD drills dominates all other drills. DI ZHANG et al. 2008 has

investigates the Aluminum-Silicon Carbide composites, effects the spatial distribution of

reinforcing elements results in the delamination of particle in highly accumulated area

increases. MAHAMANI A. 2014 deals with study of delamination in drilling of aluminum

2219 matrix with TiB2/ZrB2 reinforcement material results in drill diameter, feed rate and

decrease in surface roughness due to spindle speed and point angle. GAITONDE V N et

al. 2008 predicted that the delaminating of medium density fiberboard through drilling by

surface response method and design with Taguchi method. BASAVARAJAPPA et al.

2008 has concluded the drilling characteristics of hybrid composites by taking drilling

parameter into account. Analysis of the drilling characteristics done by using the Taguchi

design of experiments and analysis of variance. The present article physically verifies the

thrust force generated using the outcome of various drilling parameters in machining

Al/SiC-TiO2 Nano composite [ PALANIKUMAR K. AND KARTHIKEYAN R. 2007]. The titanium nitride coated HSS twist drill bit of dia 6 mm, 8 mm, and 10 mm using a

vertical machining center for conduct of experiment. Response surface model for the

above experiment are developed. The research concludes, by increasing the feed rate and

drill diameter the thrust force increases Box-Behnken Design, analysis of variance is

utilized for the cutting parameters optimization.

2. Materials and Methodology

Table 1: Aluminum alloy Composition

Elements Si Fe Cu Mn Mg Zn Cr Ti Al

Weight

(%) 0.638 0.295 0.259 0.097 0.878 0.035 0.092 0.029 Balance

Table 2. Chemical composition of Titanium oxide (TiO2, Rutile) Nano particles

Chemical composition of Aluminum alloy Al6061 has been tabulated as shown in

Table 1, and used as matrix material. The reinforcement materials such as 230 grit size of

SiC, and (20 – 50 nm) of Nano TiO2, are used for experimental fabrication. The

composites were manufactured utilizing stir casting method with 93 wt% of Al, 5 wt% of

the SiC powder and a fixed amount of 2 wt% of TiO2. Al 6061 ingot in round form were

sliced into little pieces and taken in crucible which was heated up to 850oC to get fluid

shape and after that the temperature is step by step diminished till it achieves 620oC where

TiO2 S Si Al Mg

>99.5

it accomplishes a semisolid state. Estimated amount of SiC and TiO2 particles was heated

at 720oC and added consistently with mixed aluminum liquid. The entire prepared

composite was continuously stirred at 750 revolutions per minute for 6 – 8 min and after

that the melt filled steel mould and permitted to cool to acquire 100 x 100 x 10 mm size of

plate. Sample was prepared in the shape of square plate which specification is 100 × 100 ×

10 mm. The TiN coated twist drilling bit of size 6mm, 8mm, and 10mm are used. Drilling

experiments were conducted with support of CNC Vertical Milling Centre (VMC100)

[PALANIKUMAR K et al. 2014]. The drilling sample was produced by using

specification 100 × 100 × 10 mm square block. Coated twist drilling bit of sizes, 6, 8, and

10 mm diameter were used. Dynamometer was connected by cable with three station

charge amplifier. The work piece is clamped on dynamometer which in turn fixed to the

working bench of the vertical milling machine [NOOR UL HAQ.A et al. 2008].

The experiment details are shown in table 3 and drilled Al MMCs are shown in

figure 2. Drilling was performed at 1500, 2000, 2500 (rpm) spindle speeds and 0.05, 0.075

and 0.1 feed rate (rev/min) and hence holes were created on the work piece. Drilling tasks

were performed under dry cutting conditions. Every experiment was conducted by keeping

different drill diameter, with varying feed, and speed, and the values were analyzed

[PAULO DAVIM J.2003.] By using data acquisition system, the data are collected and

recorded. With the application of dynamometer, cutting forces were constantly recorded.

Table 3: Details of Cutting Parameter

Sl.

No representation

Drilling

Parameter

Range/Level

Units 1 2 3

1. d Drill Diameter 6 8 10 mm

2. f Feed Rate 0.05 0.075 0.1 mm/rev

3. N Spindle Speed 1500 2000 2500 rpm

3. Result and Discussion

3.1 Modeling and optimization of drilling parameters using response surface

methodology

The full factorial experiment of seventeen run, with three input parameter each varies with

three input parameter and varies at three levels on Taguchi technique and design process

shown in Table 4. Drilling operation was conducted with aid of computer numerical

control Vertical Milling Centre and Box–Behnken experimental design is employed. The

parameters are chosen according to different literature study. The experiments were

conducted using TiN coated twist drill bit.

Figure 1: Shows the CNC Vertical Milling Centre in which drilling of Al 95% SiC

3% TiO2 2% combination composite of different diameter is performed.


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Thrust force exerted by drilling has been calculated by dynamometer. This

experiment verifies that Box–Behnken design is analytical tool used in the design of

experiments. This design is economical and it is alternative process to the central design

for composite. The three level of experimental value are analyzed.

Table 4: Box-Behnken design consisting of experiments for the study of three

experimental Values for Thrust Force.

Table 5: Result of ANOVA for Quadratic model subjected to Thrust force generated

during drilling of Al-SiC/ Nano TiO2 Composite.

Source Sum of

Squares

df Mean

Square

F-value p-value

Model 7.417E+05 9 82414.85 87.64 < 0.0001 significant

d-Drill

diameter

83836.60 1 83836.60 89.15 < 0.0001

f-Feed 15636.89 1 15636.89 16.63 0.0047

N-Spindle

speed

802.69 1 802.69 0.8536 0.3863

df 46010.25 1 46010.25 48.93 0.0002

dN 256.00 1 256.00 0.2722 0.6179

fN 506.25 1 506.25 0.5384 0.4870

d² 77135.25 1 77135.25 82.03 < 0.0001

f² 1425.52 1 1425.52 1.52 0.2580

N² 7839.67 1 7839.67 8.34 0.0234

Residual 6582.55 7 940.36

Lack of Fit 3031.75 3 1010.58 1.14 0.4345 not significant

Pure Error 3550.80 4 887.70

Cor Total 7.483E+05 16

Factor 1 Factor 2 Factor 3 Response 1

Std Run d: Drill diameter f: Feed C: Spindle speed Thrust Force

mm mm/rev. rpm N

1 2 6 0.05 2000 192

2 16 10 0.05 2000 423

3 11 6 0.1 2000 235

4 12 10 0.1 2000 895

5 14 6 0.075 1500 202

6 10 10 0.075 1500 702

7 7 6 0.075 2500 204

8 4 10 0.075 2500 736

9 15 8 0.05 1500 456

10 1 8 0.1 1500 767

11 8 8 0.05 2500 485

12 17 8 0.1 2500 751

13 3 8 0.075 2000 542

14 13 8 0.075 2000 551

15 9 8 0.075 2000 605

16 5 8 0.075 2000 534

17 6 8 0.075 2000 534


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Table 5. Shows the ANNOVA is employed to determine the thrust force generated

during drilling operation of Al–SiC/ Nano TiO2 Composite. The “P” value is less than

0.05 for the model indicates its acceptability at the confidence level of 95%. It is prudent

since it shows that the model terms have remarkable effect on the response. The effects of

various individual models like d, f and interaction of d and f are significant model terms.

Not significant models are N, d2, f2, N2 interaction of N with d and f respectively. The

significant index has not been evidenced while arriving the value through the analysis of

variance in turn it lead to the “lack of fit” [BASAVARAJAPPA S.2009]. Hence the

proposed model is effective in determining the drilled induced thrust force which was

developed during the drilling of Al-SiC/Nano TiO2 composite. Thrust force is influenced

to greater extent by drill diameter, followed by the feed rate and spindle speed.

3.2 Thrust Force Analysis of Nano Composite.

Figure 2 — Plot for Normal probability (a) Graph for correlation (b) Graph for

thrust force (c) Residuals Vs Run (d) Residuals Vs Predicted

Experimental model shows the conclusion of linear, square and interaction. The quadratic

design model, with experimental data relationship was build up for the thrust generated in

drilling of Al – SiC/ Nano TiO2 Composite. By taking input values of variables` for

composite in account, the model is mentioned below:

Thrust Force. (N) = -871.90000+484.71250d -14316.00000f -0.674650N +2145.00000d *

f +0.008000d * N +0.008000f * N --33.83750d² +29440.00000f ² +0.000173N2

From the figure, the development of model shows normality against externally residual. In

Fig.3 (a). Evident so as to the values obtain from the model are distributed on the line,

have shown that developed model is effective. Fig. 3(b) evident that correlation among

(a) (b)

(c) (d)


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the experimental relations made with that of determined values. The result shows that the

experimental values having close relation with empirical value produced and thus the

developed model been the beneficial prediction of cutting force produce thrust in drilling.

Fig.3 (c) evident that statistics related to residual. Externally studentized residuals

indicates the optimized surface model has been succeeded to forecast a thrust force for

three variables in drilling operation for Al-Si with nano TiO2 composites. Fig.1 (d) evident

that predicted value vs externally studentized residuals. It clearly reveals the extreme

deviation is 4.84963, and is with-in limit.

Table.6: Fit Statistics

Std. Dev. 30.67 R² 0.9912

Mean 518.47 Adjusted R² 0.9799

C.V. % 5.91 Predicted R² 0.9278

Adeq Precision 32.0482

The predicted value of square of R (0.9278) is not as nearer to the value of the square of

adjusted R (0.9799) in turn received the difference is less than 0.2, which is not desirable.

It may show that possible problem may be with a developed model or data or specify a

large block effect. Necessary object to examine are outliers, empirical model reduction etc.

The signal to noise ratio can be measured by Adeq precision. It was observed that, the

ratio was greater than 4, which is desirable. Adequate level of ratio 32.0482 was observed

during the study. Similarly, the navigation on design space can be very easily found out by

this method.

From, the given model drill diameter represents d, feed represents, f and spindle

speed represent, N. The developed model has been examined using the correlation

coefficient, R2. It evident that the residuals lies in straight line mean with the purpose of

the error are generally scattered. Since, the model produces R2 values as 0.9912 and the

adjusted R2 values as 0.9799. Thus, achieved values confirm that model is extremely

reliable. Therefore, proves the model was significant at 95% at probability level.

3.2.1 Drilling Parameter Effect Graph

(a) (b

)


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Fig.3 Drilling Parameter Effect Graph

Fig 2 clearly indicates the effect of process parameter on thrust force during drilling

operation. If feed rate increases during process leads to increase the stress on the drill bit

in the opposite direction of feed (vertical direction) as a result thrust force increased during

drilling. This is also due to increase in contact surface between the drilled portion and

circumference of drill bit which shows a thrust force increase in throughout drilling of

aluminum metal matrix composite. By increasing spindle speed, traverse rate increases

and makes the material soften which leads to reduce the thrust force in the drilling

operation. By continuous increase in spindle speed to 2500 rpm makes the thrust force

increases slightly because of heat generation at the interface of the drill bit and the contact

surface of the hole.

3.2.2 Interaction Graph Thrust Force

(c)

(a) (b)


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Fig.4 Interaction Graph Thrust Force (3D)

The figure 3 clearly shows the 3D interaction graph, which neatly gives the

prediction values of Feed rate, Spindle speed, and Drill diameter. The predicted parameter

gives the outcome of thrust force. It clearly indicates that the thrust force during drilling is

increased by increasing the feed rate, spindle speed and drill diameter. Among these three

parameters, smaller drill diameter gives the lower thrust force which is opted for drilling a

composite with low burr [PALANIKUMAR.K et al. 2015]. 3D interaction graph can be a

reliable tool to evaluate the process parameter from the given level of factors with

minimum deviation.

3.2.3 Response on contour plot:

(a)

2.3

62.

36

(c)

(b)

2.3

62.

36


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Fig.5 Estimated contour plots for thrust force

Figure 6 (a to c) shows the estimated contour plots of thrust force for Al/SiC–TiO2

Nano composites. The contour plots examined gives the value of thrust force desirability

at any region of the drilling parameters in the experimental work. Response surface model

is used to analyze the optimization of process parameters in drilling operation. This model

is derived on desirability function approach and progress by Design Experts Software. By

this approach, a large number of solution has been developed and the best solution is

preferred based on high desirability.

3.2.4 SEM images showing drilled hole surface:

Damage Surface of the drilled sample work piece has been investigated. Testing

of the drilled surface of the hole was executed by scanning electron microscope. Figure 4

shows, that machined surface was properly examined and the micro cracks, wrap, trenches

presence on the drilled surface, are found. The occurrence of microscopic cracks is due to

the strain hardening of the material. Among, the different diameter drill, Al 95% SiC 3%

TiO2 2% combination having feed rate 0.1 mm/rev, with speed 2500 rpm and drill

diameter ø6 mm reveals less occurrence of microscopic cracks. The grooves formed by the

drilling action in the composite specimen get smoother by increase in the temperature

which leads to plastic deformation of the material [BALASIVANANDHAPRABU.S et al.

2006]. Increasing the drill bit diameter from 6mm to 8mm resulted in more surface

smoothness by flattening the extrusions, thus reducing the friction coefficient also. The

asperities of the hard counter surface can be clearly seen with sharpness and corrugated

structures.

(a) (b)

(c)

2.3

62.

36


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(i) Al 95% SiC 3% TiO2 2% combination with ø10 mm

(ii) Al 95% SiC 3% TiO2 2% combination with ø8 mm

(c)

(a) (b)

(c)


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(iii) Al 95% SiC 3% TiO2 2% combination with ø6 mm Fig: 6. SEM images showing the drilled surface of Al – Si C Metal Matrix with Ti O2

Nano Composite with feed rate 0.1 mm/rev and with speed of 2500 rpm in different

drill diameter such as ø 6, ø 8, ø 10. (i) Entry (ii) Intermediate & (iii) Exit Level

3.3 Quantitative Analysis of Element

Energy dispersive spectroscopic (EDAX) has been analyses to study the composition of

element present in Al – SiC / Nano TiO2 Composite. Fig. 5. Shows EDAX spectra of

Al/SiC - Nano TiO2 Composite [Ramesh S et al. 2008].

(c)

(a) (b)


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Fig.7: The spectrum of EDAX shows he presence of the elements in the

reaction layer interface of Al – SiC TiO2 Nano Composite in Ɵ10 mm drilled surface

feed rate 0.1 mm/rev and with speed of 2500 rpm

Table 7: EDX showing the elements percentage of Al–SiC TiO2 Nano composite Ɵ10

mm drilled surface.

Net Counts

C O Al Si Ti

Base(1780)_pt1 0 662 76175 255 6

Weight %

C O Al Si Ti

Base(1780)_pt1 0.00 3.50 95.70 0.77 0.03

Atom %

C O Al Si Ti

Base(1780)_pt1 0.00 5.77 93.49 0.72 0.02


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Fig.8: The spectrum of EDAX shows he presence of the elements in the reaction layer

interface of Al – SiC TiO2 Nano Composite in Ɵ8mm drilled surface under feed rate

0.1 mm/rev and with speed of 2500 rpm


mm drilled surface.

Net Counts

C O Al Si Ti

Base(1779)_pt1 13 717 143008 76 44

Weight %

C O Al Si Ti

Base(1779)_pt1 0.28 2.10 97.38 0.13 0.12

Atom %

C O Al Si Ti

Base(1779)_pt1 0.63 3.48 95.71 0.12 0.06

Fig.9: The spectrum of EDAX shows he presence of the elements in the reaction layer

interface of Al – SiC TiO2 Nano Composite in Ɵ6mm drilled area under feed rate 0.1

mm/rev and with speed of 2500 rpm


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mm drilled surface.

Net Counts

C O Al Si Ti

Base (1778) _pt1 23 627 86187 190 13

Weight %

C O Al Si Ti

Base (1778) _pt1 0.78 2.97 95.68 0.51 0.06

Atom %

C O Al Si Ti

Base (1778) _pt1 1.71 4.86 92.92 0.47 0.03

From Table shows, the composition of elements percentage of Al–SiC TiO2

Nanocomposites. The spectrum of EDAX show evidence of the existence of the elements

aluminium, silicon titanium and carbon in the reaction layer interface shown in Figure. It

has been understood that EDAX detect little amount of oxygen extracted from an oxide

layer produced during sample preparation. It is understood from spectrum of EDX that the

peak of Al is in the order of five times higher than the peak of Si and other small peaks are

the elements Ti and O are revealed.

Table 7, reveals that Weight % of 95.70% Al, 0.77 % Silicon,0.03% titanium, 0.00%

Carbon and 3.50 % Oxide elements and Atom % of 93.49% Al, 0.72 % Silicon,0.02%

titanium, 0.00% Carbon and 5.77 % Oxide elements detected in the Ɵ10 mm drilled

surface of Al 93% SiC 5% TiO2 2% Composite sample.

Table 8, reveals that Weight % of 97.38% Al, 0.13 % Silicon,0.12% titanium, 0.28 %

Carbon and 2.10 % Oxide elements and Atom % of 95.71 % Al, 0.12 % Silicon,0.06 %

titanium, 0.63% Carbon and 3.48 % Oxide elements detected in the Ɵ8 mm drilled surface

of Al 93% SiC 5% TiO2 2% Composite sample.

Table 9, reveals that Weight % of 95.68 % Al, 0.51 % Silicon,0.06 % titanium, 0.78 %

Carbon and 2.97 % Oxide elements and Atom % of 92.92 % Al, 0.47 % Silicon,0.03 %

titanium, 1.17 % Carbon and 4.86 % Oxide elements detected in the in Ɵ6mm drilled

surface of Al 93% SiC 5% TiO2 2% Composite sample.

3.4 Surface Roughness Analysis

Atomic Force Microscope (AFM) analysis is a method to analyse the surface

roughness in its full 3D glory. This type of microscope has a rectangular probe, with a

sharp tip and this probe end captures the hole surface of very high-resolution images, it

also produces the resolution of fractions of nanometer. The gold coated silicon nitride

rectangular shape cantilever type probe measures surface roughness of drilled hole.

The AFM topographical showing (Fig.6(a)) the surface roughness in 3D image

and also shows 2D height for Al-SiC-Nano TiO2 surfaces[RAJMOHAN.T et al. 2013].

(Fig.6(b)) shows the corresponding 3D images and the peak and clustering of structure

accountable for bouncy surface and shows the ‘trench’ which can be identify with as

surface defects.


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Fig. 10 shows the examination on surface of Al – SiC / Nano TiO2 Metal Matrix

composite by Atomic Force Microscope, (a) & (b) Microstructure analysis (c) Line

image of cross-sectional position of the morphology (d) Section Analysis details

In the given sample of composite, the depth of micro cracks are evaluate and

recorded. The graph depicts the micro level cracks depth in Al – SiC / Nano TiO2 Metal

Matrix composites sample range from 0.19481µm to 0.89063µm by considerably

increasing with the pulse current and pulse on duration. Micro cracks developed after

drilling is an acceptable range, which in turn leads to assemble or further more operation

can be done in a drilled hole.

4. Conclusion Present work deals with investigational outcome during the drilling of Al / SiC - TiO2 Nano Composites on different cutting condition pertaining to thrust in drilling using TiN

coated twist drill. The conclusions are mentioned below:

1. Development of Response surface model using Box – Benken Design to correlate the drill parameter with reference to thrust force. The coefficient of correlation

0.9885 indicates that, the model developed is adequate. This proves that the model

was vital at 95% at probability and so, the models are often well utilized in Al –

SiC/ Nano TiO2 composite drilling.

2. Result of various parameters in drilling operation such as drill dia, feed rate and spindle speed of Al– SiC/ Nano TiO2 Composite has been study for thrust force

using 3D surface plots.

3. The most vital aspects in influencing the drilling process of Al / SiC - Nano TiO2 composite are feed rate and drill diameter. Feed rate and drill diameter increases,

leads in increasing of thrust force, whereas spindle rotation reduces the thrust

forces and the increases for further increasing the spindle speed.

(a) (b)

(c)

(d)


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4. The thrust force is predicted by generation of experimental model. The investigation proves that model is best suited to predict the drilling which

stimulate thrust in Al – SiC/ Nano TiO2 composite.

5. The characterization of TiO2 Nano particle in which SiC particles are dispersed in aluminum are studied using SEM and EDAX analysis. The results conclude the

existence of SiC and TiO2 Nano particle in the Al matrix composites. It also shows

that drilled surface was properly examined and the micro cracks, wrap, trenches

presence on the drilled surface, are found. The formation of microscopic cracks,

because of existence of hard SiC set on their path. Once a cluster of microscopic

cracks meet each other close to a particle, void around, set on is developed. The

spectrum of EDAX show evidence of the existence of the elements aluminum,

titanium, silicon and carbon in the reaction layer interface.

6. AFM topographic image shows the Surface profiles that are taken at three different locations of the drilled hole. With three-dimension image, the normal

grain width and height and also extreme grain width and height are measured.

More quantity of group of micro grains, le ads to measure the larger values of

width and height of the micro cracks.

5. References

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[2] Rajmohan T. and Palanikumar K.,“Experimental investigation and analysis of

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[3] Ramulu M, Nageswara Rao Posinasetti, Kao.H.“Drilling of (Al2O3) p/6061 metal

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[4] Di Zhang, Kenjiro Sugio, Kazuyuki Sakai, and Hiroshi Fukushima.,“Effect of

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study of thrust force in drilling al / sic - nano tio2 metal ...using sem and afm in analyzing of...

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