Tool life prediction model of uncoated carbide tool in high speed drilling of Al-Si alloy using response surface methodology

This paper reports on the development of a mathematical model for tool life of uncoated carbide tools during high speed drilling of Al-Si alloys. Central composite design (CCD) of experiment, coupled with response surface methodology (RSM) were used to predict the tool life in relation to the machining variables such as cutting speed and feed rate. The adequacy of the predictive model was verified by analysis of variance (ANOVA). Results show that effect of feed rate on the predicted tool life model was very significant as compared to cutting speed. It was evident that chipping at the outer cutting edge was the dominant failure mode at the highest level of feed rate employed. However, with decreasing feed rate and increasing cutting speed, non-uniform flank wear was observed to be the dominant failure mode of the uncoated carbide tool during high speed drilling of Al-Si alloy.