Title: Investigation and optimisation of machining parameters for micro-countersinking of AISI 420 stainless steel

Authors: Arshad Noor Siddiquee; Zahid A. Khan; Jagat Singh Tomar

Addresses: Mechanical Engineering Department, Jamia Millia Islamia, New Delhi – 110025, India ' Mechanical Engineering Department, Jamia Millia Islamia, New Delhi – 110025, India ' Mechanical Engineering Department, Jamia Millia Islamia, New Delhi – 110025, India

Abstract: This paper presents an experimental study in which the effect of rake angle, feed and speed on the multi-performance characteristics (index) of countersunk micro holes produced on AISI 420 suture needles was investigated. Two response variables, i.e., out-of-roundness and eccentricity of the countersunk hole were used as process performance measure. The experiments were performed according to full factorial design. Grey relational analysis coupled with principal component analysis was used to determine the index. The results of analysis of variance (ANOVA), interaction effect analysis indicated that the rake angle of -15°, feed of 11 µm/rev and speed of 6,000 rpm yielded the optimal index for the countersinking process. The results of ANOVA revealed that the interaction between feed and speed contributed maximum (33.33%) to the index for the countersinking process. The contributions of other factors and interaction between factors were: interaction between rake angle and speed (12.70%), rake angle (12.38%), interaction between rake angle and feed (10.95%), speed (7.62%) and feed (4.45%).

Keywords: microdrilling; microcountersinking; grey relational analysis; principal component analysis; PCA; micromachining; drilling; countersinking; optimisation; machining parameters; AISI 420 stainless steel; rake angle; feed rate; speed; countersunk micro holes; suture needles; out-of-roundness; eccentricity; full factorial design; grey relational analysis; GRA; ANOVA.

DOI: 10.1504/IJMMM.2013.056364

International Journal of Machining and Machinability of Materials, 2013 Vol.14 No.3, pp.230 - 256

Received: 05 May 2012
Accepted: 21 Dec 2012
Published online: 26 Dec 2013 *

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