Determination and Validation of Material Removal Rate by Actual Machining in Drilling Operation

Abstract

This research focuses on determining and validating the Material Removal Rate (MRR) by actual machining of drilling operation. Drilling operation is still widely used in the aerospace, aircraft and automotive industries although modern metal cutting methods have been developed in the manufacturing industries. MRR formula is used to calculate the weight of solid waste generated during drilling operation. This weight can be used to estimate the cost of disposal of the solid waste in a machining workshop. Hence the validation of MRR formula for drilling operation is necessary to determine how much the theoretical value away from the experimental value. In this project, three types of materials are needed to determine the MRR value. The three materials are mildsteel, aluminum and brass. The drilling operation are performed physically to determine the amount of waste generated for a specify depth of cut. High-speed steel was used as the cutting tool and the material removal rate formula of drilling operation. Machine was used: Deckel Maho DMU 50. Statistical analysis using SPSS to analysis the variance between physical value and theoretical value. The variance of the three workpiece of the same material is equal claimed as null hypothesis. The result showed that there were no significant different to reject null hypothesis as the P-value was more than 0.05 where the level of confidence is 95%. The causes for the difference of weight between the physical observation and the weight derived from the MRR formula were determined using an Ishikawa diagram.