Performance Analysis of Process Parameters and Drill Geometry in Drilling AA 6061-T6 Alloy

In the study conducted aims to investigate the effects of cutting parameters and drill helix angle on surface roughness (Ra), cutting temperature (T) and energy consumption (SEC) in drilling AA 6061-T6 alloy experimentally and statistically. Drilling experimental design was prepared using Taguchi L27 orthogonal array. Cutting parameters and drill helix angles were optimized using Ra, T and ET values. Experimental results were first evaluated with three-dimensional graphics. Obtained data were statistically analysed by performing signal/noise ratio (S/N), analysis of variance (ANOVA), regression analysis and verification tests. In addition, Ra, T and ET variables were optimized together using Grey Relational Analysis (GRA). As a result of this study, optimum Ra, T and ET values were reached in A3B3C1, A1B1C1 and A1B3C3 experimental combinations, respectively. The most effective parameters on Ra, T and ET were found to be 54.93% f, 52.02% cutting speed (Vc) and 68.12% feed rate (f) respectively. The optimum experimental combination for Ra, T and ET was A1B1C1 as a result of GRA analysis. The results predicted with the mathematical models developed as a result of the analyses were found to yield high-accuracy results. In addition, it was observed that BUE and chip adhesion generally occurred in the drill bits.