Title: Application of Box-Behnken design for the optimisation of process parameters in dry drilling operation

Authors: Subhas Chandra Mondal; Jitendra Kumar

Addresses: Department of Mechanical Engineering, Indian Institute of Engineering Science and Technology, Shibpur, Howrah 711103, West Bengal, India ' Department of Mechanical Engineering, Indian Institute of Engineering Science and Technology, Shibpur, Howrah 711103, West Bengal, India

Abstract: Drilling is one of the important fundamental metal cutting processes used in manufacturing industry for making hole in a specimen. This paper is carried out to find optimal parameter settings in dry drilling of mild steel specimen in a radial drilling machine using Box-Behnken design (BBD). The effect of the input process parameters such as speed, feed and drill diameter and their interactions on responses such as cutting force and torque are studied using second-order response surface modelling (RSM). The model analyses are done based on analysis of variance (ANOVA) and F-test, which indicate that the feed rate and interaction of feed and drill diameter is most significant on cutting force while for torque, interaction of speed and drill diameter is also significant in addition to feed rate and interaction of feed and drill diameter. Predicted value obtained using model equations are in good agreement with the experimental value of force and torque. Finally, the optimal parameter settings for force (speed 150 rpm, feed 0.29 mm/rev and drill diameter 14 mm) and torque (speed 150 rpm, feed 0.19, drill diameter 12 mm) are identified from the response plots.

Keywords: dry drilling; Box-Behnken design; BBD; response surface methodology; modelling; RSM; analysis of variance; ANOVA; optimisation; dry machining; optimisation; process parameters; mild steel; speed; feed rate; drill diameter; cutting force; torque.

DOI: 10.1504/IJPQM.2016.077777

International Journal of Productivity and Quality Management, 2016 Vol.18 No.4, pp.456 - 473

Available online: 15 Jul 2016 *

Full-text access for editors Access for subscribers Purchase this article Comment on this article