Work

Single-Step Drilling Using Novel Modified Drill Bits Under Dry, Water, and Kerosene Conditions and Optimization of Process Parameters via MOGA-ANN and RSM

Year: 2025

Type: article

Abstract: 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 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.

Source: Lubricants

DOI: 10.3390/lubricants13060273

Authors: Sumitava Paul, Barun Haldar, Hillol Joardar, Nripen Mondal, Naser Alsaleh, Maaz Akhtar

Institutions: Imam Mohammad ibn Saud Islamic University, C.V. Raman Global University, University of Kalyani

Language: English

Topic: Advanced machining processes and optimization

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $3,137

Funder: Al-Imam Muhammad Ibn Saud Islamic University