Application of Taguchi Technique to Surface-Grinding of Mold Steel

2016 ◽  
Vol 689 ◽  
pp. 7-11 ◽  
Author(s):  
Y. Şahin ◽  
Senai Yalcinkaya
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Quality Characteristics ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Machining Parameters ◽  
Taguchi Technique ◽  
Fluid Environment ◽  
Selection Of

The selection of optimum machining parameters plays a significant role for the quality characteristics of products and its costs for grinding. This study describes the optimization of the grinding process for an optimal parametric combination to yield a surface roughness using the Taguchi method. An orthogonal array and analysis of variance are employed to investigate the effects of cutting environment (A), depth of cut (B) and feed rate (C) on the surface roughness characteristics of mold steels. Confirmation experiments were conducted to verify the optimal testing parameters. The experimental results indicated that the surface finish decreased with cutting-fluid and depth of cut, but decreased with increasing feed rate. It is revealed that the cutting fluid environment had highest physical as well as statistical influence on the surface roughness (71.38%), followed by depth of cut (25.54%), but the least effect was exhibited by feed rate (1.62%).

scholarly journals Optimization of machining parameters in face milling using multi-objective Taguchi technique

2018 ◽  
Vol 12 (2) ◽  
pp. 104-108 ◽  
Author(s):  
Yusuf Fedai ◽  
Hediye Kirli Akin
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Taguchi Technique ◽  
Average Roughness ◽  
Multi Objective ◽  
Control Factors ◽  
Average Maximum

In this research, the effect of machining parameters on the various surface roughness characteristics (arithmetic average roughness (Ra), root mean square average roughness (Rq) and average maximum height of the profile (Rz)) in the milling of AISI 4140 steel were experimentally investigated. Depth of cut, feed rate, cutting speed and the number of insert were considered as control factors; Ra, Rz and Rq were considered as response factors. Experiments were designed considering Taguchi L9 orthogonal array. Multi signal-to-noise ratio was calculated for the response variables simultaneously. Analysis of variance was conducted to detect the significance of control factors on responses. Moreover, the percent contributions of the control factors on the surface roughness were obtained to be the number of insert (71.89 %), feed (19.74 %), cutting speed (5.08%) and depth of cut (3.29 %). Minimum surface roughness values for Ra, Rz and Rq were obtained at 325 m/min cutting speed, 0.08 mm/rev feed rate, 1 number of insert and 1 mm depth of cut by using multi-objective Taguchi technique.

Experimental investigations of cutting parameters’ influence on cutting forces and surface roughness in turning of Inconel alloy X-750 with biodegradable vegetable oil

2015 ◽  
Vol 231 (9) ◽  
pp. 1516-1527 ◽  
Author(s):  
Ahmadreza Hosseini Tazehkandi ◽  
Mohammadreza Shabgard ◽  
Farid Pilehvarian ◽  
Nakisa Farshfroush
Keyword(s):  
Surface Roughness ◽  
Vegetable Oil ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Inconel Alloy ◽  
Coated Carbide

Nickel-based Inconel X-750 superalloy is widely applied in aerospace industry and manufacturing of gas turbine blades, power generators and heat exchangers due to its exclusive properties. As a consequence of low heat transfer coefficient and work-hardening properties, this alloy is known as a poorly machinable alloy. In this work, effect of machining parameters (cutting speed, feed rate and depth of cut) on cutting forces and surface roughness was investigated during turning of Inconel alloy X-750 with coated carbide tool. In order to meet the demands of the environment-friendly cutting processes and human health, biodegradable vegetable oil (BioCut 4600) was selected as the cutting fluid. The results were analyzed using response surface methodology and statistical analysis of variance, and mathematical models for cutting forces and surface roughness were proposed. Results indicated that feed rate and cutting speed were the most effective parameters on the surface roughness. However, depth of cut was the most effective parameter on cutting forces in comparison with cutting speed and feed rate. Eventually, in order to achieve the main aims of industrial production in large amounts and green manufacturing, the ranges for the best cutting conditions were presented.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Multi Objective Optimization of Cutting Parameters in Machining Cellulose Based Hybrid Composites

2015 ◽  
Vol 761 ◽  
pp. 287-292
Author(s):  
Raja Izamshah ◽  
Zainudin Zuraidah ◽  
Mohd Shahir Kasim ◽  
M. Hadzley ◽  
M. Amran
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hybrid Composites ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Multi Objective Optimization ◽  
Machining Performance ◽  
Machined Surface ◽  
Multi Objective ◽  
Optimization Of Cutting Parameters

Cellulose based hybrid composites are gaining popularity in the growing green communities. With extensive studies and increasing applications for future advancement, the need for an accurate and reliable guidance in machining this type of composites has increased enormously. Smooth and defect free machined surface are always the ultimate objectives. The present work deals with the study of machining parameters (i.e. spindle speed, feed rate and depth of cut) and their effects on machining performance (i.e. surface roughness and delamination) to establish an optimized setup of machining parameters in achieving multi objective machining performance. Cellulose based hybrid composites consist of jute (a bast fiber) and glass fiber embedded in polyester resins. Response Surface Methodology (RSM) using Box-Behnken Design (BBD) was chosen as the design of experiment approach for this study. Based on that experimental approach, 17 experimental runs were conducted. Mathematical model for each response was developed based on the experimental data. Adequacy of the models were analyzed statistically using Analysis of Variance (ANOVA) in determining the significant input variables and possible interactions. The multi objective optimization was performed through numerical optimization, and the predicted results were validated. The agreement between the experimental and selected solution was found to be strong, between 95% to 96%, thus validating the solution as the optimal machining condition. The findings suggest that feed rate was the main factor affecting surface roughness and delamination .

Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

2009 ◽  
Vol 407-408 ◽  
pp. 608-611 ◽  
Author(s):  
Chang Yi Liu ◽  
Cheng Long Chu ◽  
Wen Hui Zhou ◽  
Jun Jie Yi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

scholarly journals The Experimental Investigation of Surface Roughness After Dry Turning of Steel S235

2019 ◽  
Vol 26 (4) ◽  
pp. 179-184
Author(s):  
Justyna Molenda
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Scientific Work ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material ◽  
Important Indicator

AbstractNowadays lot of scientific work inspired by industry companies was done with the aim to avoid the use of cutting fluids in machining operations. The reasons were ecological and human health problems caused by the cutting fluid. The most logical solution, which can be taken to eliminate all of the problems associated with the use of cooling lubricant, is dry machining. In most cases, however, a machining operation without lubricant finds acceptance only when it is possible to guarantee that the part quality and machining times achieved in wet machining are equalled or surpassed. Surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered as one of the most important parameter in industry. Today the quality of surface finish is a significant requirement for many workpieces. Thus, the choice of optimized cutting parameters is very important for controlling the required surface quality. In the present study, the influence of different machining parameters on surface roughness has been analysed. Experiments were conducted for turning, as it is the most frequently used machining process in machine industry. All these parameters have been studied in terms of depth of cut (ap), feed rate (f) and cutting speed (vc). As workpiece, material steel S235 has been selected. This work presents results of research done during turning realised on conventional lathe CDS 6250 BX-1000 with severe parameters. These demonstrate the necessity of further, more detailed research on turning process results.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

scholarly journals Research on selection of abrasive grain size and cutting parameters when grinding of interrupted surface using aluminum oxide grinding wheel with ceramic binder

2022 ◽  
pp. 93-102
Author(s):  
Do Duc Trung ◽  
Le Dang Ha
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Aluminum Oxide ◽  
Feed Rate ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Testing Sample ◽  
Abrasive Grain ◽  
Ceramic Binder

In this article, a study on intermittent surface grinding using aluminum oxide grinding wheel with ceramic binder is presented. The testing material is 20XH3A steel (GOST standard – Russian Federation). The testing sample has been sawn 6 grooves, with the width of each groove of 10 mm, the grooves are evenly distributed on the circumference of sample. The testing sample resembles a splined shaft. An experimental matrix of nine experiments has been built by Taguchi method, in which abrasive grain size, workpiece speed, feed rate and depth of cut were selected as input variables. At each experiment, surface roughness (Ra) and roundness error (RE) have been measured. Experimental results show that the aluminum oxide and ceramic binder grinding wheels are perfectly suitable for grinding intermittent surface of 20XH3A steel. Data Envelopment Analysis based Ranking (DEAR) method has been used to solve the multi-objective optimization problem. The results also showed that in order to simultaneously ensure minimum surface roughness and RE, abrasive grain size is 80 mesh, workpiece speed is 910 rpm, feed rate is 0.05 mm/rev and depth of cut is 0.01 mm. If evaluating the grinding process through two criteria including surface roughness and RE, depth of cut is the parameter having the greatest effect on the grinding process, followed by the influence of feed rate, workpiece speed, and abrasive grain is the parameter having the least effect on the grinding process. In addition, the effect of each input parameter on each output parameter has also been analyzed, and orientations for further works have also been recommended in this article

scholarly journals The influence of machining parameters on surface roughness of MDF in milling operation

BioResources ◽  
2019 ◽  
Vol 14 (2) ◽  
pp. 3266-3277
Author(s):  
Ümmü K. İşleyen ◽  
Mehmet Karamanoğlu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Medium Density Fiberboard ◽  
Spindle Speed ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Operation ◽  
Four Levels ◽  
Tool Diameter

This paper examined the effect of machining parameters on surface roughness of medium density fiberboard (MDF) machined using a computer numerical control (CNC) router. The machining parameters such as spindle speed, feed rate, depth of cut, and tool diameter were examined for milling. The experiments were conducted at two levels of spindle speeds, four levels of feed rates, two levels of tool diameters, and two levels of axial depths of cut. The surface roughness values of MDF grooved by CNC were measured with stylus-type equipment. Statistical methods were used to determine the effectiveness of the machining parameters on surface roughness. The influence of each milling parameter affecting surface roughness was analyzed using analysis of variance (ANOVA). The significant machining parameters affecting the surface roughness were the feed rate, spindle speed, and tool diameter (p < 0.05). There was no significant influence of axial depth of cut on the surface roughness. The surface roughness decreased with increasing spindle speed and decreasing feed rate. The value of surface roughness increased with the increase of tool diameter.

Optimisation of Machining Parameters for Milling Polyetheretherketones (PEEK) Biomaterial

2014 ◽  
Vol 699 ◽  
pp. 198-203 ◽  
Author(s):  
Raja Izamshah Raja Abdullah ◽  
Aaron Yu Long ◽  
Md Ali Mohd Amran ◽  
Mohd Shahir Kasim ◽  
Abu Bakar Mohd Hadzley ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Processing Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dimensional Precision ◽  
Good Surface

Polyetheretherketones (PEEK) has been widely used as biomaterial for trauma, orthopaedic and spinal implants. Component made from Polyetheretherketones generally required additional machining process for finishing which can be a problem especially to attain a good surface roughness and dimensional precision. This research attempts to optimize the machining and processing parameters (cutting speed, feed rate and depth of cut) for effectively machining Polyetheretherketones (PEEK) implant material using carbide cutting tools. Response Surface Methodology (RSM) technique was used to assess the effects of the parameters and their relations towards the surface roughness values. Based on the analysis results, the optimal machining parameters for the minimum surface roughness values were by using cutting speed of 5754 rpm, feed rate of 0.026 mm/tooth and 5.11 mm depth of cut (DOC).

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