MULTI OBJECTIVE OPTIMIZATION OF BTA DEEP HOLE DRILLING PROCESS PARAMETERS USING RESPONSE SURFACE METHODOLOGY

In this work an attempt has been made to drill Aluminium casting using BTA (Boring Trepanning Association) deep hole drilling tool and optimize the deep hole drilling process parameters using ‘Response Surface Methodology (RSM)’. BTA machining is capable of drilling holes having large length to diameter ratio in a single pass. The present work deals with optimization of surface roughness (Ra) and Metal Removal Rate (MRR) of BTA machined Aluminium components using RSM. Experiments were carried out over a wide range of cutting conditions and the effect of various process parameters like spindle speed, feed rate and depth of cut using Box - Behnken design of experimental design technique. Results are analyzed using Analysis of Variance (ANOVA) and response surface considering individually output parameters such as Metal Removal Rate (MRR) and surface roughness (Ra). ANOVA and r esponse surface analyses indicated that combinations of BTA deep hole drilling process parameters such as high speed, high feed and high depth of cut resulted in higher Metal Removal Rate (MRR), whereas low speed, low feed and low depth of cut resulted in lower Ra in Aluminium casting material. The output of this work will be useful for manufacturing engineers in deep hole drilling of Aluminium casting material which finds its application in various mechanical fields like automobile, aerospace, defense, et c.