Single-Step Drilling Using Novel Modified Drill Bits Under Dry, Water, and Kerosene Conditions and Optimization of Process Parameters via MOGA-ANN and RSM
The burr removal and finishing of drilled hole walls typically require multiple post-processing steps. This experimental study introduces a novel single-step drilling approach using modified drill bits for simultaneous burr removal and surface finishing in aluminum 6061-T6. The odified-1 drill, equi...
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| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-06-01
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| Series: | Lubricants |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-4442/13/6/273 |
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| Summary: | The burr removal and finishing of drilled hole walls typically require multiple post-processing steps. This experimental study introduces a novel single-step drilling approach using modified drill bits for simultaneous burr removal and surface finishing in aluminum 6061-T6. The odified-1 drill, equipped with a deburring micro-insert, achieved superior results, with a chamfer height of −2.829 mm, drilling temperature of 40.28 ◦C, and surface roughness of 0.082 µm under optimal conditions. Multi-objective optimization using the RSM and MOGA-ANN identified the optimal drilling parameters for the Modified-1 drill at 3000 rpm under water lubrication as compared to dry conditions and kerosene. Experimental validation confirmed the high prediction accuracy, with deviations under 6%. These results establish the Modified-1 twist drill bit with a deburring<br> micro-insert as a highly effective tool for burr-free high-quality drilling in a single operation. This innovative drill design presents an efficient, single-step solution for burr elimination, chamfer formation, and surface finishing in drilling operations. |
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| ISSN: | 2075-4442 |