Optimization of thrust force, torque, and tool wear in drilling of coir fiber-reinforced composites using Nelder-Mead and genetic algorithm methods

Machining of composite materials is an important and current topic in modern researches on manufacturing processes. Determination of optimal cutting parameters is one of the most important elements in the machinability study of composites. Optimization has significant practical importance particularly for operating the machineries. In order to increase the accuracy of drill holes, the tool must be in good condition always as much as possible. To achieve good condition of tool, the optimization of machining parameters like drill bit diameter, spindle speed, and feed rate are mandatory. The objective of this paper is to study the effect of these process parameters on thrust force, torque, and tool wear in drilling of coir fiber-reinforced composites. The optimal settings of the parameters were determined through experiments planned, conducted, and analyzed using the Box-Behnken design, Nelder-Mead, and genetic algorithm methods. This paper also aimed to increase the cutting condition of tool, i.e., minimization of tool wear by applying the optimized input parameters using Nelder-Mead and genetic algorithm techniques.