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Optimization of cutting parameters on drill bit

temperature in drilling by Taguchi method

Article in Measurement · November 2013

DOI: 10.1016/j.measurement.2013.06.046

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 Measurement 46 (2013) 3525–3531

Contents lists available at SciVerse ScienceDirect

Measurement
journal homepage: www.elsevier.com/locate/measurement

Optimization of cutting parameters on drill bit temperature

in drilling by Taguchi method
Ramazan Çakıroğlu a,⇑, Adem Acır b
a _ Meslek Yüksek Okulu, Ankara, Turkey
Gazi Universitesi, OSTIM
b
Gazi Universitesi, Teknoloji Fakültesi, Teknikokullar, Ankara, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: In this study, the optimization of the cutting parameters on drill bit temperature in drilling
Received 5 February 2013 was performed. Al 7075 work piece and the uncoated and FirexÒ coated carbide drills in the
Received in revised form 7 May 2013 experimental were used. The optimization of the cutting parameters was evaluated by
Accepted 25 June 2013
Taguchi method. The control factors were considered as the cutting speed, feed rate and
Available online 3 July 2013
cutting tool. Taguchi method was used to determining the settings of cutting parameters.
The L18 orthogonal array was used in experimental planning. The most significant control
Keywords:
factors affected on drill bit temperature measurements was obtained by using analysis of
Taguchi method
Regression analysis
variance (ANOVA). Taguchi design method exhibit a good performance in the optimization
ANOVA of cutting parameters on drill bit temperature measurements. In addition, the empirical
Drill bit temperature equations of drill bit temperatures were derived by using regression analysis. The obtained
Drilling equations results compared with the drill bit temperature measurement results. The
empirical equations results indicated a good agreement with experimental results.
Ó 2013 Elsevier Ltd. All rights reserved.

1. Introduction finite element thermal model [5]. Ueda et al. measured

The thermo-mechanical effect is very important in the
machining. The thermo-mechanical effect occurs during
material removal processes as plastic deformation of the
work piece and the friction along the tool-chip interface
[1,2]. The effect occurred during material removal pro-
cesses leads to heat generation in the cutting zone. In the
machining, the most of the heat occurred in the cutting
zone is removed by the chips [3,4]. The friction between
the work piece and tool causes the higher temperature in
the cutting zone. The higher temperature occurred in the
cutting zone can significantly shorten the tool life [4].
Therefore, several papers have been published on
prediction and measurement of temperature in the drilling
process. Li and Shih investigated heat occured on the
drill–chip contact in drilling process and modeled using a
⇑ Corresponding author. Tel.: +90 312 354 84 01.
E-mail addresses: rcakiroglu@gazi.edu.tr (R. Çakıroğlu), adema@
gazi.edu.tr (A. Acır).
the temperature of the cutting edges of a drill and the ef-
fect of the temperature occurred drill was investigated
[6]. Measurement of cutting edge temperature in drilling
was performed by Beno and Hulling [7]. Zeilmann et al.,
have presented a study of the temperature occured during
drilling of the titanium alloy Ti6Al4V with K10 carbide
drills [8]. The temperature profile along the cutting edges
of a drill using finite element method was analyzed by
Bono and Ni [9]. The other study, the face of a twist drill
using an experimental technique that measures average
drill flank temperatures were developed by the Agapiou
and DeVries [10]. Previous studies were shown that dril-
ling process is important tool life and cost. Therefore, the
optimization depend on cutting parameters in machining
can be decrease the machining cost and time.
In this study, the modeling and optimization of cutting
parameters on drill bit temperature measurements in dril-
ling process of Al 7075 alloys were investigated by using
the Taguchi design method. The most cutting parameters
on drill bit temperatures were performed by using the

0263-2241/$ - see front matter Ó 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.measurement.2013.06.046
3526 R. Çakıroğlu, A. Acır / Measurement 46 (2013) 3525–3531

Nomenclature

PCR percent contribution ratio DoF degrees of freedom

Ve variance of error SS sequential sum of squares
tA degrees of freedom MS mean sum of squares
SST sum of squares
T drill bit temperature, °C Subscripts
V cutting speed, m/min A parameter
F feed rate, mm/rev T total
S/N signal-to-noise
g S/N ratio

analysis of signal-to-noise (S/N) ratio and ANOVA analysis,

respectively. And also, the drill bit temperature results ob- Coolant hole
tained as experimental and the results of the regression
analysis (RA), obtained empirical equations, are compared. Thermocouple Thermocouple
wire Drill bit

2. Materials and method Fig. 2. The twist drilling tool and thermocouple inserted through the hole
of internal coolant carbide drill [18].
2.1. Materials, measurement and drilling test conditions

The experimental setup for measuring the temperatures
during drilling was shown in Figs. 1 and 2. The drilling
experiments were performed in dry conditions on Johnford
CNC vertical milling using uncoated and FirexÒ coated car-
bide twist drilling tools. FirexÒ product was a multi-layer
coating that combines TiN, TiAlN, and TiCN. The point an-
gle of a twist drill is 140° and drill diameter was 14 mm.
As test specimen material in drilling process, the Al 7075
alloy bar was used with 25 mm in diameter and 25 mm
in length. The spectrum analysis of Al 7075 alloy used in
the experiments was given in Table 1. Drill bit temperature
measurements in these experiments were used K type
thermocouples with a diameter of 1 mm. Measurement
ranges K type (NiCr–Ni) thermocouples used in these
experiments was 200° to 1200° with ±0.05% measure-
ment accuracy and its response time was 10 ls. The fixed
drill and rotated workpiece (specimen) application was
used in the experiments. As shown in Fig. 2, the thermo-
couples was inserted through the coolant hole inside of
the drills and the thermocouple used through the coolant
hole was fixed near to the drill bit surface. The drilling tests
were performed at the different drill types (uncoated and
FirexÒ coated), cutting speed and feed rates. The drilling
tests were done through work piece. The cutting parameter
levels used the design experiment based on Taguchi meth-
od for Al 7075 alloy drilling tests were given as shown in
Table 2.
2.2. Taguchi method

The Taguchi method is experimental design method.

The Taguchi design procedure is shown in Fig. 3. The Tagu-
chi design procedure consists of three stages as system,

Table 1
Chemical composition of the workpiece material (Al 7075) (% weight).

Si Fe Cu Mn Mg Cr Zn Ti Al
0.257 0.397 3.392 0.653 0.446 0.099 0.002 0.012 94.71
Workpiece
Thermocouple Dynamometer
wire Drill
Table 2
Assignment of the levels to the factors.

Symbol Machining parameter Levels

Machine Table 1 2 3
A Tool Uncoated Coated –
B Feed rate, f (mm/rev) 0.1 0.2 0.3
Fig. 1. CNC vertical milling machine and measurement method used in C Cutting Speed, Vc (m/min) 170 200 230
the experimental study [18].
 R. Çakıroğlu, A. Acır / Measurement 46 (2013) 3525–3531 3527

ters using the L18 orthogonal array is shown in Table 3.

Taguchi design The S/N ratio was used to measure the quality characteris-
method tic deviating from the desired value. The objective function
in this work was the-lower-the-better quality characteris-
tics for obtaining optimal cutting performance, the signal-
to-noise (S/N) ratio defined with the Taguchi method:
!
1X n
g ¼ 10 log y2 ð1Þ
System design Parameter design Tolerance design n i¼1 i

where g is the S/N ratio for the lower-the-better case (unit:

dB), and yi represents the drill bit temperatures based on
experimental results and n the number of repetitions in a
Select proper Orthogonal array

design by tightening the tolerance

trial [15,16]. The corresponding S/N ratio obtained from
Determine suitable working

Determine results of Parameter

levels of the design factors

Eq. (1) and the experimental results obtained for drill bit
Run experiments
temperature were illustrated in Table 4. The S/N analysis

ofthesignif icantfactor
was based on the experimental data.
Analyze data

3. Results and discussion

Identify optimum conditions

3.1. Analysis of variance (ANOVA)

Confirmation runs

The purpose of the ANOVA analysis is to determine of

Fig. 3. Taguchi design procedure [11,12]. effect the design parameters on quality characteristic
[16]. The drill bit temperatures are performed by ANOVA
to identify the most influential factors in the cutting
parameter, and tolerance design as shown in Fig. 3. The
parameters. In this study, the application of ANOVA is to
parameter design is the most important stage [11–13].
investigate drill bit temperatures and the percent contribu-
The parameter design is contributed to determine the ef-
tion ratio (PCR). The identified cutting parameters and
fect of the control factor in drilling process. The parameter
their associated levels are given in Table 2 for optimization.
design is contributed to evaluate the optimal cutting con-
In machining, cutting parameters have a significant effect
ditions of obtaining the lowest drill bit temperature. The
in the experimental results. In order to see this effect
control factors and each parameter used the experimental
clearly, the PCR indicating the degree of influence of cut-
design based on Taguchi method for Al 7075 alloy machin-
ting parameters in the experimental drill bit temperature
ing tests used in the experiments were given as shown in
test results is calculated from Eq. (2) [17], and obtained re-
Table 2. Three factors for drill bit temperature measure-
sults are analyzed.
ments as the main machining parameters were selected  
and it were considered as tool types, cutting speeds and SSA  ðV e Þ:ðtA Þ
PCR ¼  100 ð2Þ
feed rates. In addition, an L18 orthogonal array with three SST
columns and eighteen rows was used in the present anal-
ysis. The experimental layout for the machining parame-

Table 4
Table 3 Experimental results and S/N ratio, (g), for drill bit temperature.
Experimental design using L18 orthogonal array.
Exp. Tools Feed Cutting Temperature S/N (dB)
Experiment No. A (Tool) B (Feed rate) C (Cutting speed) No. rate speed (°C)

1 1 1 1 1 Uncoated 0.1 170 198 45.9333

2 1 1 2 2 Uncoated 0.1 200 214 46.6083
3 1 1 3 3 Uncoated 0.1 230 247 47.8539
4 1 2 1 4 Uncoated 0.2 170 141 42.9844
5 1 2 2 5 Uncoated 0.2 200 153 43.6938
6 1 2 3 6 Uncoated 0.2 230 161 44.1365
7 1 3 1 7 Uncoated 0.3 170 112 40.9844
8 1 3 2 8 Uncoated 0.3 200 121 41.6557
9 1 3 3 9 Uncoated 0.3 230 145 43.2274
10 2 1 1 10 Coated 0.1 170 146 43.2871
11 2 1 2 11 Coated 0.1 200 154 43.7504
12 2 1 3 12 Coated 0.1 230 176 44.9103
13 2 2 1 13 Coated 0.2 170 140 42.9226
14 2 2 2 14 Coated 0.2 200 148 43.4052
15 2 2 3 15 Coated 0.2 230 153 43.6938
16 2 3 1 16 Coated 0.3 170 128 42.1442
17 2 3 2 17 Coated 0.3 200 136 42.6708
18 2 3 3 18 Coated 0.3 230 141 42.9844
3528 R. Çakıroğlu, A. Acır / Measurement 46 (2013) 3525–3531

Table 5 Table 6
Results of ANOVA for drill bit temperature. S/N response table (g) for drill bit temperature (smaller is better).

Source DoF SS MS F- P- PCR Symbol Parameter Mean S/N ratio, g

test value (%)
Level 1 Level 2 Level 3 Max–
Tool 1 2.968 2.9678 3.30 0.094 4.18 min
Feed rate 2 29.590 14.7950 16.46 0 56.15
A Tool 44.12 43.31 – 0.81
Cutting 2 6.154 3.0772 3.42 0.067 8.80
B Feed rate, f (mm/ 45.39 43.47 42.28 3.11
speed
rev)
Residual 12 10.786 0.8988 30.87
C Cutting speed, Vc 43.04 43.63 44.47 1.43
error
(m/min)
Total 17 49.498 100

DoF: degrees of freedom; SS: sequential sum of squares; MS: mean sum of
squares.

Table 7
Results of confirmation tests for drill bit temperature.
where SSA is the sum of squares for parameter A, V e is the
Initial cutting Optimal cutting
variance of error, tA is the degrees of freedom of parameter parameters parameters
A, and SST is the total sum of squares [17]. The PCR of the
Prediction Experimental
cutting parameters on the drill bit temperature were
shown in Table 5. ANOVA analysis is performed for a 5% Level A2B2C2 A2B3C1 A2B3C1
Temperature, (°C) 148 108.889 128
(P < 0.05) significance level, i.e., for a 95% confidence level S/N ratio (dB) 43.4052 41.2007 42.1441
to identify the cutting parameters that affect the drill bit Improvement of 1.2611 dB
temperature. Statistically, F-tests provided a decision at S/N ratio
some confidence level that is the realized significance lev- Prediction error 0.9434
(dB)
els, for each source of variation as shown in Tables 5. The F-
test and P value illustrated that the variation of the process
parameter made a big change on the performance charac- situation. In addition, the largest S/N ratio would be the
teristics [12–14]. According to Table 5, feed rates were ideal situation and the optimum cutting conditions was
found to be the major factor affecting the drill bit temper- determined by the level average responses from the S/N
atures (PCR: 56.15%) whereas, cutting speeds were found ratio for drill bit temperatures. The analysis was done by
to be the second important factor (PCR: 8.80%). But, a tool the S/N ratio at each level of each factor. The obtained
type shows a little effect on the drill bit temperature. As a analysis results were plotted in an S/N response graphical
result, feed rates of the drill bit temperature are found as form for drill bit temperatures. As seeing in a graphical
the most effective parameters. In addition, it can be seen forms (see Fig 4), the optimum conditions corresponds to
that the residual error containing all the major parameters cutting parameter level were shown as the peak point. In
from ANOVA results was 30% as shown in Table 5. addition, S/N response table were given in Table 6 for each
level of the cutting parameters as the mean S/N ratio. The
3.2. Determination of the optimum drilling conditions effects of all three control factors with levels derived from
Table 6 were shown in Fig. 4. The comparison of the pre-
The effect of each factor at different levels can be deter- dicted drill bit temperature with the actual drill bit tem-
mined by averaging the S/N ratios in the experiments. In perature using the optimal cutting parameters were
this study, it is the-smaller-the-better case, which means illustrated in Table 7. The improvement in S/N ratio from
the smallest drill bit temperature would be the ideal the initial cutting parameters to the level of optimal cut-
Mean of S/N ratios, dB

Signal-to-noise: Smaller is better

Level 1 Level 2 Level 1 Level 2 Level 3 Level 1 Level 2 Level 3

Fig. 4. Mean S/N ratio graph for drill bit temperature.

 R. Çakıroğlu, A. Acır / Measurement 46 (2013) 3525–3531 3529

f0,1 f0,2 f0,3

Vc170 Vc200 Vc230
275
275

225 225

Temperature (°C)
Temperature (°C)

175 175

125 125

75 75
0,1 0,2 0,3 170 200 230
f, mm/rev Vc, m/min

Fig. 5. Drill bit temperature for uncoated carbide drills.

ting parameters was 1.2611 dB. The values of drill bit 3.3. Correlation
temperature between initial and experimental cutting
parameters were decreased by 1.15 times. Therefore, the The correlations between the feed rate and cutting
values of drill bit temperature were greatly improved by speed and the measured cutting temperature were ob-
using the Taguchi approach. In addition, the optimal tained by regression analysis. The drill bit temperature
combination of levels for the criteria of the lowest equations obtained with regression analysis using MINI-
response and lowest S/N ratio were determined as TAB 14 software were as follows:
A2B3C1 for the ideal drill bit temperature as presented Uncoated drill bit temperature (°C):
in Table 7. The coated tool at level 2, the feed rate at level
T ð CÞ ¼ 93  203  f þ 0:833  V þ 1:33  f  V ð3Þ
3 and the cutting speed at level 1 on cutting parameters
provided the best results for optimum drilling conditions Coated drill bit temperature (°C):
as regards drill bit temperature.
T ð CÞ ¼ 55 þ 151  f þ 0:594  V  1:42  f  V ð4Þ

Vc170 Vc200 Vc230 f0,1 f0,2 f0,3

225 225

175 175
Temperature (°C)

Temperature (°C)

125 125

75 75
0,1 0,2 0,3 170 200 230
f, mm/rev Vc, m/min

Fig. 6. Drill bit temperature for FirexÒ coated carbide drills.

3530 R. Çakıroğlu, A. Acır / Measurement 46 (2013) 3525–3531

where f is the feed rate in mm/rev, V the cutting speed in

Experimental RA Training RA Testing
m/min. 300

Temperature (°C)
250
200
3.4. Confirmation test
150
100
The drill bit temperature is very important factor in the 50
tool wear, surface quality and cost. As shown in Figs. 5 and 0
6, the drill bit temperatures were given for different cut- 1 2 3 4 5 6 7 8 9
ting speeds and feed rates. Drill bit temperatures increased Experimental number
with increasing cutting speed whereas, the temperatures
decreased with increasing feed rates. Increasing feed rate Fig. 9. Comparison of experimental and predicted temperature values for
uncoated drill tools.
and decreasing cutting speed led to higher chip removal
rate. The heat energy occurred from friction in the drill–
chip contact interface was carried away with increasing
Experimental RA Training RA Testing
feed rate. Therefore, increasing feed rate and decreasing
200
cutting speed led to a decrease in drill bit temperature

Temperature (°C)
175
the along the drill–chip interface due to higher chip re-
moval rate. In addition, tool coating will not change the 150

drill bit temperature directly but alters the friction in the
drill–chip contact. The most important parameter for
change the drill bit temperature is a different thermal con-
ductivity between with and without coating.
In confirmation tests, the obtained experimental drill
bit temperature values were divided into two parts and
these parts constitute training and testing data in this
study. The experimental data set consists of 9 values for
both uncoated and coated drills. Total experimental num-
ber is 18. The 7 values are used for training of the RA
whereas, the 2 values is performed for testing of the RA.
The empirical Eqs. (3), (4) using the training data for the
prediction of drill bit temperature by RA was obtained.
On the other hand, the testing data for in the confirmation
tests with obtained empirical Eqs. (3), (4) were performed.
Fig. 7. Comparison of regression model results with experimental results
for drill bit temperature with FirexÒ coated carbide drill.
125
100
75
1 2 3 4 5 6 7 8 9
Experimental number
Fig. 10. Comparison of experimental and predicted temperature values
for coated drill tools.
A comparison of prediction results with experimental tem-
perature results were shown in Figs. 7 and 8 for uncoated
and coated cutting tools. Both training data and testing
data were compared in this figure. The predicted tempera-
ture values obtained with empirical Eqs. (3), (4) for both
training data and testing data values were very close to
corresponding experimental results as shown in Figs. 7
and 8. The obtained results of both experiment and models
show the small deviation less. As seen clearly from Figs. 7
and 8, the obtained RA models were illustrated as a feasible
and an effective way for the prediction of drill bit temper-
ature in drilling process. The R2 in testing data for temper-
ature prediction in the RA model is computed as 0.9799
and 0.9044 for coated and uncoated drills, respectively.
As a result, the empirical equations results obtained from
RA were indicated a good agreement with experimental re-
sults. In addition, the experimental results and obtained
drill bit temperature with RA models are also plotted in
Figs. 9 and 10, as comparatively for both training data
and testing data. Except some small shifts from the center
line the dots form almost a straight line in all the plots. As a
result of the graphs the presented models fit the data well.

4. Conclusions

In this paper, the optimization of cutting parameters on

drill bit temperature in drilling process by using the
Taguchi method were performed. The main results were
as follows:

 The drill bit temperature increased with increasing cut-

Fig. 8. Comparison of regression model results with experimental results ting speed whereas, the drill bit temperature decreased
for drill bit temperature with uncoated carbide drill. with increasing feed rates for both two type drill.
 R. Çakıroğlu, A. Acır / Measurement 46 (2013) 3525–3531
 According to ANOVA results, the most significant factor
in affecting the drill bit temperature was the feed rate
having a percentage contribution of 56.15%.
 An optimum parameter combination for the lower drill
bit temperature was obtained by using the analysis of
signal-to-noise (S/N) ratio. The optimum cutting condi-
tions for drill bit temperature were determined as cut-
ting speed 170 m/min, feed rate 0.3 mm/min with
coated drill.
 The confirmation experiments were performed to verify
the optimal cutting parameters. The improvement of
drill bit temperature from the initial cutting parameters
to the optimal cutting parameters was about 1.15 times.
 Taguchi experimental design method was an efficient
and effective method for optimizing drill bit tempera-
ture in a drilling process.
 The empirical equations for the prediction of drill bit
temperature by multi-variable RA were developed. In
the confirmation tests, RA empirical equations have
indicated a good agreement with experimental results.
 Taguchi design method, RA was able to provide the
minimum cost and time in the manufacturing engineer-
ing applications.
Acknowledgement
This work has been supported by Scientific Research
Project Unit of Gazi University (G.Ü. BAP, 07/2010-24).
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