Optimization of process parameters for improving drilling quality and machining performance of abrasive assisted drilling on AISI D2 steel

33-41This research is concerned with optimization of roughness and material removal rate, as a result of AISI D2 steel drilling with abrasive assisted high speed steel drill. Experimentation include drilling of AISI D2 steel with supply of Sic and Al2O3 abrasive slurry having mesh size 800, 1200 and 1500 with slurry concentration of 20, 25, and 35%. The drilling parameters namely types of abrasive, abrasive mesh size, spindle speed, slurry concentration and feed rate were optimized using L18 orthogonal array for surface roughness and material removal rate. Analysis of variance is employed to find the percentage contributions of each control parameters. The results show that the type of abrasives and abrasive mesh size are the most significant factors which affect the roughness of drilled hole walls. The material removal rate affects significantly by feed rate and type of abrasive. The performance in the conventional drilling can be effectively improved by using hybrid drilling