Optimization of end mill tool geometry parameters for Al7075-T6 machining operations based on vibration amplitude by response surface methodology

Measurement ◽  
2013 ◽  
Vol 46 (10) ◽  
pp. 4005-4022 ◽  
Author(s):  
M. Subramanian ◽  
M. Sakthivel ◽  
K. Sooryaprakash ◽  
R. Sudhakaran
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Vibration Amplitude ◽  
Tool Geometry ◽  
End Mill ◽  
Machining Operations

Modeling and Optimization of Vibration Amplitude in Turning of Ti-6Al-4V Using Response Surface Methodology

2012 ◽  
Vol 217-219 ◽  
pp. 1567-1570
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Syidatul Akma Sulaiman
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Vibration Amplitude ◽  
Desirability Function ◽  
Cutting Speed ◽  
Vibration Sensor ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Work Piece ◽  
Inferior Surface

Chatter is detrimental to turning operations and leads to inferior surface topography, reduced productivity, dimensional accuracy, and shortened tool life. Avoidance of chatter has mostly been through reliance on heuristics such as: limiting material removal rates or selecting low spindle speeds and shallow depth of cuts. But, modern industries demand increased output and not steady operational limits. Various research efforts have therefore focused on developing mathematical models for chatter formation. However, as yet there is no existent model that meets all experimental verification. This research employed a novel technique based on the synergy of statistical modeling and experimental investigations in order to develop an effective empirical mathematical model for chatter amplitude and to subsequently find optimal machining conditions. Ti-6Al-4V, Titanium alloy, was used as the work-piece due to its increased popularity in applications related to aerospace, automotive, nuclear, medical, marine etc. A sequence of 15 experimental runs was conducted based on a small Central Composite Design (CCD) model in Response Surface Methodology (RSM). The primary (independent) parameters were: cutting speed, feed, and depth of cut. The tool overhang was kept constant at 70 mm. An engine lathe (Harrison M390) was employed for turning purposes. The data acquisition system comprised a vibration sensor (accelerometer) and a signal conditioning unit. The resultant vibrations were analyzed using the DASYLab 5.6 software. The best model was found to be quadratic which had a confidence level of 95% (ANOVA) and insignificant Lack of Fit (LOF) in Fit and Summary analyses. Desirability Function (DF) approach predicted minimum vibration amplitude of 0.0276 Volts and overlay plots identified two preferred machining regimes for optimal vibration amplitude.

Surface Roughness Analysis of Carbon/Glass Hybrid Polymer Composites in Drilling Process Based on Taguchi and Response Surface Methodology

2015 ◽  
Vol 1119 ◽  
pp. 622-627 ◽  
Author(s):  
Chye Lih Tan ◽  
Azwan Iskandar Azmi ◽  
Noorhafiza Muhammad
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Regression Model ◽  
Response Surface ◽  
Feed Rate ◽  
Hybrid Composite ◽  
Spindle Speed ◽  
Tool Geometry ◽  
Secondary Process ◽  
Drilling Process

Drilling is an essential secondary process for near net-shape of hybrid composite as to achieve the required dimensional tolerances prior to final application. Dimensional tolerance is often influenced by the surface integrity or surface roughness of the workpart. Thus, this paper aims to employ the Taguchi and response surface methodologies in minimizing the surface roughness of drilled carbon-glass hybrid fibre reinforced polymer (CGCG) using tungsten carbide, K20 drill bits. The effects of spindle speed, feed rate and tool geometry on surface roughness were evaluated and optimum cutting conditions for minimizing the aforementioned response was determined. Subsequently, response surface methodology (RSM) was utilised in finding the empirical relationships between experimental parameters and surface roughness based on the Taguchi results. The experimental analyses reveal that surface roughness is greatly influenced by feed rate and tool geometry rather than the spindle speed. This is due to the increment of feed that attributed to the increased strain rate and hence, deteriorated the surface roughness of the hybrid composite. The predicted results (via regression model) and theoretical results (via additivity law) were in good agreement with experiment results. This indicates that the regression model from response surface methodology (RSM) can be used to predict the surface roughness in machining of CGCG hybrid composite.

COMPLEXITY-BASED ANALYSIS OF THE INFLUENCE OF TOOL GEOMETRY ON CUTTING FORCES IN ROUGH END MILLING

Fractals ◽  
2018 ◽  
Vol 26 (05) ◽  
pp. 1850078 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Fractal Structure ◽  
End Milling ◽  
Complex Structure ◽  
Tool Geometry ◽  
Machining Parameters ◽  
End Mill ◽  
Force Signal ◽  
Machining Operations

It is known that geometry of cutting tool affects the cutting forces in machining operations. In addition, the value of cutting forces changes during machining operations and creates a chaotic time series (signal). In this paper, we analyze the variations of the complex structure of cutting force signal in rough end milling operation using fractal theory. In fact, we analyze the variations of cutting force signal due to variations of tool geometry (square end mill versus serrated end mill). In case of each type of end mill, we did the machining operation in wet and dry conditions. Based on the results, the fractal structure of cutting force signal changes based on the type of milling tool. We also did the complexity analysis using approximate entropy to check the variations of the complexity of cutting force signal, where the similar behavior of variations between different conditions was obtained. The method of analysis that was used in this research can be applied to other machining operations to study the influence of different machining parameters on variations of fractal structure of cutting force.

Experimental Investigation Using Response Surface Methodology for Condition Monitoring of Misaligned Rotor System

2021 ◽  
pp. 1-9
Author(s):  
Shital Patil ◽  
Arun K Jalan ◽  
Amol Marathe
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
System Performance ◽  
Significant Variation ◽  
Vibration Amplitude ◽  
Axial Direction ◽  
Response Factor ◽  
Rotating System ◽  
Remarkable Effect ◽  
System Vibration

Abstract Misalignment is one of the key reasons for vibrations in most of the rotating system. The present work focuses on interactions between speed, load, and defect severity by investigating their effect on the system vibration. Response Surface Methodology (RSM) with Root Mean Square (RMS) as a response factor is used to understand the influence of such interactions on the system performance. Experiments are planned using design of experiments and analysis is carried out using Analysis of Variance (ANOVA). It is observed that, speed has a remarkable effect on RMS value in both parallel and angular type of misalignment and affects the system performance. RSM results revealed that a change in load has less impact on vibration amplitude in case of horizontal and vertical directions but there is significant variation in RMS value in axial direction for both type of misalignment. A slight increase in RMS value with increase in defect severity is observed in axial direction. These observations will help to understand the misalignment defect and its effect in a better way.

scholarly journals Modeling of Cutting Parameters and Tool Geometry for Multi-Criteria Optimization of Surface Roughness and Vibration via Response Surface Methodology in Turning of AISI 5140 Steel

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4242 ◽  
Author(s):  
Mustafa Kuntoğlu ◽  
Abdullah Aslan ◽  
Danil Yurievich Pimenov ◽  
Khaled Giasin ◽  
Tadeusz Mikolajczyk ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Prediction Models ◽  
High Reliability ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Tool Geometry ◽  
Machining Processes

AISI 5140 is a steel alloy used for manufacturing parts of medium speed and medium load such as gears and shafts mainly used in automotive applications. Parts made from AISI 5140 steel require machining processes such as turning and milling to achieve the final part shape. Limited research has been reported on the machining vibration and surface roughness during turning of AISI 5140 in the open literature. Therefore, the main aim of this paper is to conduct a systematic study to determine the optimum cutting conditions, analysis of vibration and surface roughness under different cutting speeds, feed rates and cutting edge angles using response surface methodology (RSM). Prediction models were developed and optimum turning parameters were obtained for averaged surface roughness (Ra) and three components of vibration (axial, radial and tangential) using RSM. The results demonstrated that the feed rate was the most affecting parameter in increasing the surface roughness (69.4%) and axial vibration (65.8%) while cutting edge angle and cutting speed were dominant on radial vibration (75.5%) and tangential vibration (64.7%), respectively. In order to obtain minimum vibration for all components and surface roughness, the optimum parameters were determined as Vc = 190 m/min, f = 0.06 mm/rev, κ = 60° with high reliability (composite desirability = 90.5%). A good agreement between predicted and measured values was obtained with the developed model to predict surface roughness and vibration during turning of AISI 5140 within a 10% error range.

scholarly journals Parametric Optimization of Butt Welded Polycarbonate using Response Surface Methodology

2021 ◽  
Vol 40 (1) ◽  
pp. 38-52
Author(s):  
Abid Imtiaz ◽  
Adnan Tariq ◽  
Ajaz Bashir Janjua ◽  
Fahad Sarfraz ◽  
Amar ul Hassan Khawaja
Keyword(s):  
Mechanical Properties ◽  
Response Surface Methodology ◽  
Solid State ◽  
Response Surface ◽  
Process Parameters ◽  
Base Material ◽  
Welding Process ◽  
Tool Geometry ◽  
Work Piece ◽  
Friction Stir

Friction Stir Welding (FSW) is a solid-state joining process for metals, non-metals and polymers. It is carried out with the help of a specially designed, non-consumable tool. The heat required, for creating a softened region at the faying surfaces, is generated by rotation of tool against the work piece material. Being a solid-state welding process, it offers several advantages like inducing minimum effect on the mechanical properties of base material, reduced shrinkage and distortion, no spatter or Ultra Violet (UV) radiations etc. However, developing a sound weld requires an appropriate combination of several process parameters e.g. the design of tool, its rotational and traversing speeds etc. To substantiate this aspect, an approach based on Response Surface Methodology (RSM) is presented during this paper that optimizes the combination of process parameters while investigating their effect on the mechanical properties of a friction stir welded butt joint configuration of Polycarbonate. To minimize the total number of combinations a Central Composite Rotatable Design (CCRD) is used with three factors and two levels. The results have shown that the butt joints fabricated at a traverse speed of 14 mm/min, rotational speed of 1700 RPM and with simple cylindrical conical tool geometry yielded the maximum ultimate tensile strength of 51.299 MPa.

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