Influence of drilling parameters on hole quality in the aluminum alloy AA6013-T651

Abstract The drilling of AA6013-T651 aluminum alloy presents challenges due to its specific processing difficulties and performance requirements. Optimizing drilling parameters is crucial for achieving high-quality machined surfaces, meeting engineering specifications, and reducing overall machining costs. Effective parameter optimization can lead to energy savings, reduced material waste, shorter processing times, and extended tool life. In this study, drilling experiments were conducted on AA6013-T651 material using three different parameters, each at three distinct levels. Maximum thrust force, time, and required power were measured during the drilling process. Following the experiments, diameter deviations were evaluated. The experimental results were analyzed using the response surface methodology (RSM), and regression analysis, analysis of variance (ANOVA), and optimization studies were carried out. The results showed that higher speeds and feeds increased cutting forces and energy consumption. Cooling strategy, particularly liquid cooling, plays a critical role in balancing efficiency with dimensional and thermal control.