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Optimization of Internal Chip Evacuation Cutting Tool System for Deep Bottle Holes Based on Chip Morphology Control.

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Optimizing Gun Drilling Parameters for Oxygen-Free Copper Using Response Surface Methodology and Genetic Algorithm.

Xiaolan Han1, Hailong Wang1, Yazhou Feng1,2

  • 1Mechanical Engineering College, Xi'an Shiyou University, Xi'an 710065, China.

Materials (Basel, Switzerland)
|August 28, 2025
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Summary

Optimizing gun drilling of oxygen-free copper enhances chip removal. Multi-objective optimization identified ideal parameters for efficient machining, minimizing chip evacuation coefficient and volume ratio.

Keywords:
gun drillingoxygen-free copperresponse surface methodology-genetic algorithm

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Mechanical Engineering

Background:

  • Efficient chip removal is critical for high-performance drilling, especially in materials like oxygen-free copper.
  • Suboptimal chip evacuation can lead to tool wear, reduced surface finish, and decreased drilling efficiency.

Purpose of the Study:

  • To optimize gun drilling process parameters for oxygen-free copper to improve chip removal efficiency.
  • To minimize the chip evacuation coefficient and chip volume ratio using multi-objective optimization.

Main Methods:

  • Utilized Box-Behnken Design (BBD) for response surface analysis to assess feed rate, cutting speed, and fluid pressure effects.
  • Employed a genetic algorithm for multi-objective optimization to determine optimal drilling parameters.
  • Developed a three-dimensional predictive model based on response surface methodology.

Main Results:

  • Feed rate was identified as the most influential parameter, followed by cutting speed and cutting fluid pressure.
  • Significant interaction effects were observed between cutting speed and cutting fluid pressure on chip evacuation and volume.
  • Optimal parameters: feed rate 0.019 mm/r, spindle speed 47.1 m/min, cutting fluid pressure 2.4 MPa.
  • Achieved chip evacuation coefficient of 3.2951 and chip volume ratio of 3.3345 with predominantly C-shaped chips.

Conclusions:

  • The study successfully optimized gun drilling parameters for oxygen-free copper, significantly improving chip evacuation.
  • The identified optimal parameters and predictive model offer a pathway to enhanced machining efficiency and performance.
  • The findings contribute to advanced manufacturing techniques for copper alloys.