Optimal drilling of particulate metal matrix composites based on experimental and numerical procedures

An experimental and numerical study of the evolution of cutting forces, tool wear and surface finish, measured when drilling the particulate metal matrix composite A356/20/SiCp-T6 is presented. The experimental work was developed through the continuous measurement of the cutting forces with an appropriate piezoelectric dynamometer. The wear type was identified and its evolution with cutting time was measured. Drills with polycrystalline diamond were tested. The surface finish of the holes was evaluated with a profilometer. Using the experimental results, a numerical search of optimal drilling conditions was performed. Since there are contradictory objectives, such as maximisation of tool life and minimisation of tool wear, the concept of the Pareto optimum solution is considered in the optimisation procedure. An evolution strategy is adopted to obtain the optimal solution for cutting speed, feed rate and tool life prediction with industrial interest. (C) 2000 Elsevier Science Ltd. All rights reserved.