Dimensional Analysis of Form Drilling Parameters by Buckingham Pi Theorem and Optimization of Heat Generation in Form Drilling Process by Taguchi

Form drilling, a novel method of hole-making process, is performed on aluminum 8011 work material with tungsten carbide conical tool. The thrust force and torque are measured by varying the process parameters such as speed, feed, diameter of tool, thickness of work material, and magnesium powder. Temperature of the workpiece during the operation is measured by infrared thermometer. The objective of this study is to identify the most effective parameters which give a cylindrical-shaped bushing without significant radial fracture or petal formation and effect of the heat generated during bushing formation in form drilling. Taguchi method is applied to optimize the influencing parameters in form drilling for heat generation. The influencing parameter affecting heat generated in form drilling is investigated by using ANOVA, and the same is confirmed by confirmation test of Taguchi method of analysis. The experimental results show that the process variable speed influence is more followed by feed. It is observed that Mg powder, workpiece thickness, tool diameter, speed, and feed affect the petal height formation by 2.98, 0.77. 85.85, 1.83, and 1.68%, respectively. Among all the process variables, tool diameter influence is more, and after the tool diameter, the influencing parameter is Mg powder.