Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussions
3.1. Design of Experiment and Optimization
3.2. Predictive Modelling
3.3. Analysis of Variance (ANOVA)
3.4. Simulations of the Hole Roundness Error
4. Conclusions
- The empirical mathematical models show a high correlation despite the large number of cases considered; the models may prove useful under industrial conditions when drilling parameters are selected;
- The kinematic system is reported to have a considerable (65.23%) effect on the roundness error of holes drilled in 42CrMo4 + QT steel;
- The Taguchi L27 orthogonal array design can be successfully used to assess the influence of the input process parameters (cutting speed and feed per revolution) and the type of kinematic system on the output parameters (hole cylindricity, straightness, roundness, and diameter errors);
- The kinematic system has a substantial effect on the roundness error—for the third kinematic system, the hole roundness error was high (min. 3.6 µm, max. 5.1 µm); however, for the first kinematic system, its values were small (min = 3.2 µm, max = 4.7 µm);
- The first kinematic system is the most suitable because three out of four output parameters reached the lowest values (CYL = 12.5 µm, STR = 11.3 µm, RON 4.0 µm);
- Future research will focus on the surface texture of holes and burr formation at the exits for different kinematic systems.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Nomenclature
DOE | design of experiment |
feed rate (mm/min) | |
spindle speed (rpm) | |
feed per revolution (mm/rev) | |
cutting speed (m/min) | |
depth of cut (mm) | |
KIN | kinematics |
SS | Sum of Squares |
DF | Degrees of Freedom |
MS | Mean Square |
CYL | CYLindricity deviation (µm) |
STR | STRaightness deviation (µm) |
RON | ROuNdness deviation (µm) |
DE | Diameter Error (µm) |
UPR | Undulations per revolution |
F | wave length |
p | significance |
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Specification | |
---|---|
Cutting edge diameter | 6 mm |
Cutting material | VHM |
Coating | TiAlNPlus |
Type | HPC UNI |
Coolant supply | Internal |
Tool holding device | HA parallel shank |
Point angle | 140° |
Shaft diameter | 6 mm |
Chip flute length | 44 mm |
DIN | 6537 |
C | Mn | Si | P | S | Cr | Ni | Mo |
---|---|---|---|---|---|---|---|
0.38–0.45 | 0.6–0.9 | 0.1–0.4 | Max. 0.035 | Max. 0.035 | 0.9–1.2 | Max. 0.3 | 0.15–0.25 |
Parameter | Value |
---|---|
Measurement range X | 900 mm |
Measurement range Y | 1200 mm |
Measurement range Z | 700 mm |
MPE_E | 0.9 + L/350 µm |
MPE_P | 1.0 µm |
MPE_RONt | 1.0 µm |
MPE_THP | 1.9 µm |
Experiment No. | Sample Code | vc, m/min | fn, mm/rev | KIN |
---|---|---|---|---|
1 | TiI1 | 90 | 0.14 | 1 |
2 | TiII1 | 90 | 0.14 | 2 |
3 | TiIII1 | 90 | 0.14 | 3 |
4 | TiI2 | 75 | 0.14 | 1 |
5 | TiII2 | 75 | 0.14 | 2 |
6 | TiIII2 | 75 | 0.14 | 3 |
7 | TiI3 | 60 | 0.14 | 1 |
8 | TiII3 | 60 | 0.14 | 2 |
9 | TiIII3 | 60 | 0.14 | 3 |
10 | TiI4 | 90 | 0.12 | 1 |
11 | TiII4 | 90 | 0.12 | 2 |
12 | TiIII4 | 90 | 0.12 | 3 |
13 | TiI5 | 75 | 0.12 | 1 |
14 | TiII5 | 75 | 0.12 | 2 |
15 | TiIII5 | 75 | 0.12 | 3 |
16 | TiI6 | 60 | 0.12 | 1 |
17 | TiII6 | 60 | 0.12 | 2 |
18 | TiIII6 | 60 | 0.12 | 3 |
19 | TiI7 | 90 | 0.1 | 1 |
20 | TiII7 | 90 | 0.1 | 2 |
21 | TiIII7 | 90 | 0.1 | 3 |
22 | TiI8 | 75 | 0.1 | 1 |
23 | TiII8 | 75 | 0.1 | 2 |
24 | TiIII8 | 75 | 0.1 | 3 |
25 | TiI9 | 60 | 0.1 | 1 |
26 | TiII9 | 60 | 0.1 | 2 |
27 | TiIII9 | 60 | 0.1 | 3 |
Experimental Results | Predicted Results | |||||||
---|---|---|---|---|---|---|---|---|
Sample Code | CYL 15 UPR, µm | STR F2.5, µm | RON 15 UPR, µm | DE, µm | CYL 15 UPR, µm | STR F2.5, µm | RON 15 UPR, µm | DE, µm |
TiI1 | 9.7 | 10.4 | 4.1 | 0.0 | 11.8 | 11.8 | 4.4 | 0.4 |
TiII1 | 12.7 | 11.8 | 3.9 | 0.8 | 13.2 | 13.2 | 4.2 | 0.3 |
TiIII1 | 12.7 | 11.8 | 3.6 | 0.5 | 13.9 | 13.0 | 3.6 | 0.7 |
TiI2 | 14.4 | 15.7 | 4.7 | −1.0 | 12.0 | 10.9 | 4.5 | −0.9 |
TiII2 | 12.1 | 12.5 | 4.5 | −0.7 | 12.5 | 12.3 | 4.6 | −0.9 |
TiIII2 | 15.6 | 14.3 | 5.0 | −0.5 | 12.3 | 12.1 | 4.5 | −0.3 |
TiI3 | 16.3 | 11.6 | 4.2 | −0.7 | 14.5 | 12.6 | 4.0 | −1.1 |
TiII3 | 13.2 | 14.3 | 4.7 | −1.3 | 14.1 | 14.0 | 4.6 | −0.9 |
TiIII3 | 10.7 | 11.2 | 4.8 | 0.2 | 13.0 | 13.8 | 5.0 | −0.1 |
TiI4 | 7.5 | 7.4 | 4.4 | −0.6 | 7.9 | 9.0 | 4.2 | −0.5 |
TiII4 | 9.8 | 9.6 | 4.4 | −0.7 | 10.5 | 10.7 | 4.1 | −0.5 |
TiIII4 | 14.5 | 14.6 | 3.7 | 0.5 | 12.3 | 10.9 | 3.7 | 0.1 |
TiI5 | 9.8 | 9.5 | 4.1 | −1.1 | 9.2 | 9.9 | 4.1 | −1.5 |
TiII5 | 12.7 | 12.0 | 5.1 | −0.9 | 10.9 | 11.6 | 4.4 | −1.3 |
TiIII5 | 12.2 | 11.0 | 4.2 | −0.4 | 11.9 | 11.8 | 4.5 | −0.5 |
TiI6 | 10.3 | 12.7 | 3.3 | −1.2 | 12.9 | 13.5 | 3.5 | −1.3 |
TiII6 | 12.9 | 13.6 | 3.6 | −1.7 | 13.8 | 15.2 | 4.3 | −0.9 |
TiIII6 | 13.6 | 17.6 | 4.8 | −0.3 | 13.9 | 15.4 | 4.8 | 0.0 |
TiI7 | 12.5 | 10.6 | 3.9 | 0.1 | 10.8 | 9.1 | 3.9 | −0.1 |
TiII7 | 14.8 | 13.2 | 4.0 | −0.4 | 14.6 | 11.2 | 4.0 | 0.1 |
TiIII7 | 18.6 | 11.3 | 3.9 | 1.1 | 17.7 | 11.8 | 3.8 | 0.8 |
TiI8 | 13.7 | 11.2 | 3.4 | −0.5 | 13.4 | 11.9 | 3.7 | −0.7 |
TiII8 | 13.9 | 13.0 | 4.0 | −0.4 | 16.3 | 14.0 | 4.2 | −0.4 |
TiIII8 | 12.7 | 9.8 | 4.1 | −0.4 | 18.5 | 14.6 | 4.5 | 0.5 |
TiI9 | 16.8 | 16.8 | 3.2 | −0.9 | 18.4 | 17.2 | 3.0 | −0.2 |
TiII9 | 24.2 | 21.6 | 4.3 | 1.2 | 20.4 | 19.4 | 4.0 | 0.3 |
TiIII9 | 24.6 | 21.7 | 5.1 | 1.9 | 21.7 | 20.0 | 4.7 | 1.4 |
Source | SS | DF | MS | F Value | p Value | Percentage Contribution |
---|---|---|---|---|---|---|
Model | 273.4319 | 9 | 30.3813 | 4.3652 | 0.0044 | 69.80 |
Constant | 110.5175 | 1 | 110.5175 | 15.8793 | 0.0010 | 28.21 |
vc | 25.2424 | 1 | 25.2424 | 3.6269 | 0.0739 | 6.44 |
vc2 | 8.3230 | 1 | 8.3230 | 1.1959 | 0.2894 | 2.12 |
fn | 84.6735 | 1 | 84.6735 | 12.1660 | 0.0028 | 21.61 |
fn2 | 72.5696 | 1 | 72.5696 | 10.4269 | 0.0049 | 18.52 |
KIN | 3.8754 | 1 | 3.8754 | 0.5568 | 0.4657 | 0.99 |
KIN2 | 0.7585 | 1 | 0.7585 | 0.1090 | 0.7453 | 0.19 |
17.7633 | 1 | 17.7633 | 2.5523 | 0.1286 | 4.53 | |
9.3633 | 1 | 9.3633 | 1.3453 | 0.2621 | 2.39 | |
17.0408 | 1 | 17.0408 | 2.4484 | 0.1361 | 4.35 | |
Error | 118.3177 | 17 | 6.9599 | - | - | 30.20 |
Total | 391.7496 | 26 | - | - | - | 100 |
Source | SS | DF | MS | F Value | p Value | Percentage Contribution |
---|---|---|---|---|---|---|
Model | 190.1672 | 9 | 21.1297 | 3.3826 | 0.0147 | 64.17 |
Constant | 62.6015 | 1 | 62.6015 | 10.0218 | 0.0056 | 21.12 |
vc | 34.7515 | 1 | 34.7515 | 5.5633 | 0.0306 | 11.73 |
vc2 | 10.4896 | 1 | 10.4896 | 1.6793 | 0.2123 | 3.54 |
fn | 27.7256 | 1 | 27.7256 | 4.4385 | 0.0503 | 9.36 |
fn2 | 13.3007 | 1 | 13.3007 | 2.1293 | 0.1627 | 4.49 |
KIN | 5.2795 | 1 | 5.2795 | 0.8452 | 0.3708 | 1.78 |
KIN2 | 3.6296 | 1 | 3.6296 | 0.5811 | 0.4563 | 1.22 |
39.9675 | 1 | 39.9675 | 6.3983 | 0.0216 | 13.49 | |
0.0008 | 1 | 0.0008 | 0.0001 | 0.9909 | 0.00 | |
1.7633 | 1 | 1.7633 | 0.2823 | 0.6021 | 0.60 | |
Error | 106.1913 | 17 | 6.2465 | - | - | 35.83 |
Total | 296.3585 | 26 | - | - | - | 100 |
Source | SS | DF | MS | F Value | p Value | Percentage Contribution |
---|---|---|---|---|---|---|
Model | 5.0664 | 9 | 0.5629 | 4.0080 | 0.0067 | 67.97 |
Constant | 0.3853 | 1 | 0.3853 | 2.7432 | 0.1160 | 5.17 |
vc | 0.7158 | 1 | 0.7158 | 5.0964 | 0.0374 | 9.60 |
vc2 | 0.3424 | 1 | 0.3424 | 2.4379 | 0.1369 | 4.59 |
fn | 0.0359 | 1 | 0.0359 | 0.2557 | 0.6196 | 0.48 |
fn2 | 0.0007 | 1 | 0.0007 | 0.0053 | 0.9430 | 0.01 |
KIN | 2.0899 | 1 | 2.0899 | 14.8796 | 0.0013 | 28.04 |
KIN2 | 0.1157 | 1 | 0.1157 | 0.8241 | 0.3767 | 1.55 |
0.1408 | 1 | 0.1408 | 1.0027 | 0.3307 | 1.89 | |
2.2533 | 1 | 2.2533 | 16.0434 | 0.0009 | 30.23 | |
0.4033 | 1 | 0.4033 | 2.8717 | 0.1084 | 5.41 | |
Error | 2.3877 | 17 | 0.1405 | - | - | 32.03 |
Total | 7.4541 | 26 | - | - | - | 100 |
Source | SS | DF | MS | F Value | p Value | Percentage Contribution |
---|---|---|---|---|---|---|
Model | 13.3653 | 9 | 1.4850 | 5.0831 | 0.0020 | 72.91 |
Constant | 4.8993 | 1 | 4.8993 | 16.7698 | 0.0008 | 26.73 |
vc | 2.7386 | 1 | 2.7386 | 9.3740 | 0.0071 | 14.94 |
vc2 | 1.9646 | 1 | 1.9646 | 6.7247 | 0.0189 | 10.72 |
fn | 3.5198 | 1 | 3.5198 | 12.0478 | 0.0029 | 19.20 |
fn2 | 2.5785 | 1 | 2.5785 | 8.8260 | 0.0086 | 14.07 |
KIN | 0.1896 | 1 | 0.1896 | 0.6491 | 0.4316 | 1.03 |
KIN2 | 0.4446 | 1 | 0.4446 | 1.5219 | 0.2341 | 2.43 |
1.6875 | 1 | 1.6875 | 5.7761 | 0.0279 | 9.21 | |
0.3333 | 1 | 0.3333 | 1.1410 | 0.3004 | 1.82 | |
0.3333 | 1 | 0.3333 | 1.1410 | 0.3004 | 1.82 | |
Error | 4.9666 | 17 | 0.2922 | - | - | 27.09 |
Total | 18.3319 | 26 | - | - | - | 100 |
Kinematic System | |||
---|---|---|---|
Parameter, Average Value | KIN I | KIN II | KIN III |
CYL, µm | 12.5 | 13.8 | 15.2 |
STR, µm | 11.3 | 13.2 | 13.3 |
RON, µm | 4.0 | 4.4 | 4.2 |
DE, µm | −0.7 | −0.4 | 0.3 |
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Bronis, M.; Miko, E.; Nowakowski, L. Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel. Materials 2021, 14, 4046. https://doi.org/10.3390/ma14144046
Bronis M, Miko E, Nowakowski L. Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel. Materials. 2021; 14(14):4046. https://doi.org/10.3390/ma14144046
Chicago/Turabian StyleBronis, Mateusz, Edward Miko, and Lukasz Nowakowski. 2021. "Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel" Materials 14, no. 14: 4046. https://doi.org/10.3390/ma14144046