Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al-PE) Using Taguchi Orthogonal Array Design

Area of Science:

• Materials Science
• Manufacturing Engineering
• Mechanical Engineering

Background:

• Aluminum Matrix Composites (AMCs) are vital in automotive, aerospace, and electronics.
• Micro-drilling is critical for fabricating components from these advanced materials.
• Understanding drilling parameters is key to optimizing performance and minimizing defects.

Purpose of the Study:

• Investigate thrust force, burr formation, tool wear, and hole diameter in micro-drilling Al-PE composite panels.
• Analyze the influence of cutting speed, feed rate, tool diameter, and tool point angle.
• Evaluate the effect of AlTiN coating on drilling performance.

Main Methods:

• Utilized Taguchi's L16 orthogonal array for experimental design.
• Conducted micro-drilling tests on aluminum-polyethylene (Al-PE) composite panels.
• Measured thrust force, burr height, tool wear, and hole diameter using ANOVA.

Main Results:

• Tool point angle was the dominant factor influencing thrust force at the composite entrance and exit.
• Cutting speed significantly affected the tool in the polyethylene core layer.
• AlTiN coating reduced tool wear and hole deviations but increased burr height.

Conclusions:

• Tool geometry and cutting parameters critically influence micro-drilling outcomes in Al-PE composites.
• AlTiN coating offers benefits for tool longevity but requires process adjustments to manage burr formation.
• Optimizing these parameters is essential for high-precision manufacturing of composite components.