Experimental investigation and analysis of machinability behaviour of hybrid GFRP composites during end milling

2016 ◽  
Vol 45 (3) ◽  
pp. 206-214
Author(s):  
M.P. Jenarthanan ◽  
A. Lakshman Prakash ◽  
R. Jeyapaul
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Response Surface ◽  
End Milling ◽  
Surface Model ◽  
End Mill ◽  
Gfrp Composites ◽  
Content Type ◽  
Gfrp Composite ◽  
Solid Carbide

Purpose This paper aims to develop a mathematical model for analysing surface roughness during end milling by using response surface methodology (RSM) and to determine how the input parameters (cutting speed, depth of cut and feed rate) influence the output parameter (surface roughness) in the machining of hybrid glass fibre reinforced plastic (GFRP; Abaca and Glass) composite by using solid carbide end mill cutter. Design/methodology/approach Three factors and a three-level Box–Behnken design in RSM were used to carry out the experimental investigation. Handysurf E-35A was used to measure the surface roughness of the machined hybrid GFRP composites. The “Design Expert 8.0” was used to analyse the data collected graphically. Analysis of variance was carried out to validate the model and determine the most significant parameter. Findings The response surface model was used to predict the input factors influencing the surface roughness of the machined surfaces of hybrid GFRP composite at different cutting conditions with a chosen range of 95 per cent confidence intervals. Analysis of the influences of the entire individual input machining parameters on the surface roughness carried out using RSM. Originality/value The effect of the milling of hybrid GFRP composite on the surface roughness with solid carbide end mill by using RSM has not been analysed yet.

Multi-objective optimisation on end milling of hybrid fibre-reinforced polymer composites using GRA

2017 ◽  
Vol 46 (3) ◽  
pp. 194-202 ◽  
Author(s):  
M.P. Jenarthanan ◽  
Raahul Kumar S ◽  
Vinoth S
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Helix Angle ◽  
Inspection System ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Content Type ◽  
Gfrp Composite ◽  
Solid Carbide

Purpose This study aimed to develop a mathematical model for delamination and surface roughness during end milling by using grey relational analysis (GRA) and to determine how the input parameters (cutting speed, depth of cut, helix angle and feed rate) influence the output response (delamination and surface roughness) in machining of hybrid glass fibre-reinforced plastic (GFRP) (abaca and glass) composite using solid carbide end mill cutter. Design/methodology/approach The Four factors, three levels Taguchi orthogonal array design in GRA is used to conduct the experimental investigation. The Shop Vision inspection system is used to measure the width of maximum damage of the machined hybrid GFRP composite. The Shop Handysurf E-35A surface roughness tester is used to measure the surface roughness of the machined hybrid GFRP composite. “Minitab 14” is used to analyse the data collected graphically. Analysis of variance is conducted to validate the model in determining the most significant parameter. Findings The GRA is used to predict the input factors influencing the delamination and surface roughness on the machined surfaces of the hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination and surface roughness has been conducted using GRA. Originality/value Effect of milling of the hybrid GFRP composite on delamination and surface roughness with various helix angle solid carbide end mill has not been analysed yet using the GRA technique.

Experimental investigation and analysis of factors influencing delamination and surface roughness of hybrid GFRP laminates using Taguchi technique

2016 ◽  
Vol 45 (6) ◽  
pp. 463-475 ◽  
Author(s):  
M.P. Jenarthanan ◽  
A. Lakshman Prakash ◽  
R. Jeyapaul
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
End Mill ◽  
Content Type ◽  
Cutting Parameter ◽  
Gfrp Composite ◽  
Solid Carbide

Purpose The paper aims to develop a mathematical model for delamination and surface roughness during end milling by using response surface methodology (RSM) and to determine how the input parameters (cutting speed, depth of cut, helix angle and feed rate) influence the output response (delamination and surface roughness) in machining of hybrid glass fibre reinforced plastic (GFRP; Abaca and Glass) composite using solid carbide end mill cutter. Design/methodology/approach Four-factor, three-level Taguchi orthogonal array design in RSM is used to carry out the experimental investigation. The “Design Expert 8.0” is used to analyse the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter. Findings The feed rate is the cutting parameter which has greater influence on delamination (88.39 per cent), and cutting speed is the cutting parameter which has greater influence on surface roughness (53.42 per cent) for hybrid GFRP composite materials. Both surface roughness and delamination increase as feed rate increases, which means that the composite damage is larger for higher feed rates. Originality/value Effect of milling of hybrid GFRP composite on delamination and surface roughness with various helix angles of solid carbide end mill has not been analysed yet using RSM.

Mathematical modeling of delamination factor on end milling of hybrid GFRP composites through RSM

2016 ◽  
Vol 45 (5) ◽  
pp. 371-379 ◽  
Author(s):  
M.P. Jenarthanan ◽  
A. Lakshman Prakash ◽  
R. Jeyapaul
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Gfrp Composites ◽  
Content Type ◽  
Gfrp Composite ◽  
Solid Carbide ◽  
Mill Cutter

Purpose This paper aims to develop a mathematical model for delamination during end milling by using response surface methodology (RSM) and to determine how the input parameters (cutting speed, depth of cut and feed rate) influence the output response (delamination) in machining of hybrid glass fibre reinforced plastic (GFRP; abaca and glass) composite using solid carbide end mill cutter. Design/methodology/approach Three factors, three levels Box–Behnken design in RSM is used to carry out the experimental investigation. Shop microscope Mitutoyo TM-500 is used to measure the width of maximum damage of the machined hybrid GFRP composites. The “Design Expert 8.0” is used to analyse the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter. Findings The RSM is used to predict the input factors influencing the delamination on the machined surfaces of hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination has been carried out using RSM. Originality/value Effect of milling of hybrid GFRP composite on delamination with solid carbide end mill has not been analysed yet using RSM.

Multi-objective optimization in end milling of GFRP composites using Taguchi techniques with principal component analysis

2017 ◽  
Vol 13 (1) ◽  
pp. 58-70 ◽  
Author(s):  
M.P. Jenarthanan ◽  
R. Gokulakrishnan ◽  
B. Jagannaath ◽  
P. Ganesh Raj
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Principal Component ◽  
Helix Angle ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Gfrp Composites ◽  
Content Type ◽  
Machining Force

Purpose The purpose of this paper is to find out the optimum machining parameters using Taguchi technique with principal component analysis (PCA) during end milling of GFRP composites. Design/methodology/approach In multi-objective optimization, weight criteria of each objective are important for producing better and accurate solutions. This method has been employed for simultaneous minimization of surface roughness, cutting force and delamination factor. Experiments were planned using Taguchi’s orthogonal array with the machining parameters, namely, helix angle of the end mill cutter, spindle speed, feed rate and depth of cut were optimized with considerations of multiple response characteristics, including machining force, surface roughness and delamination as the responses. PCA is adopted to find the weight factors involved for all objectives. Finally analysis of variance concept is employed on multi-SN ratio to find out the relative significance of machining parameter in terms of their percentage contribution. Findings The multi-SN ratio is achieved by the product of weight factor and SN ratio to the performance characteristics in the utility concept. The results show that a combination of machining parameters for the optimized results has helix angle of 35°, machining speed of 4,000 m/min, feed rate of 750 mm/rev and depth of cut of 2.0 mm. Originality/value Effect of milling of GFRP composites on delamination factor, surface roughness and machining force with various helix angle solid carbide end mill has not been analysed yet using PCA techniques.

Mathematical modeling of delamination factor on drilling of ARALL composites through RSM

2017 ◽  
Vol 13 (4) ◽  
pp. 578-589 ◽  
Author(s):  
M.P. Jenarthanan ◽  
Karthikeyan M. ◽  
Naresh Neeli
Keyword(s):  
Response Surface ◽  
Measuring System ◽  
Surface Model ◽  
Machining Parameters ◽  
Content Type ◽  
Solid Carbide ◽  
Fiber Metal ◽  
Tool Diameter ◽  
Central Composite ◽  
Individual Input

Purpose The purpose of this paper is to develop a mathematical model for delamination during drilling by using a response surface methodology (RSM) and also to determine how the input parameters (tool diameter, spindle speed and feed rate) influence the output response (delamination) in machining of fiber metal laminates. Design/methodology/approach Three factors and a three-level central composite design in RSM are used to carry out the experimental investigation. A video measuring system is used to measure the width of maximum damage of the machined FML composite. The “Design Expert 7.0” is used to analyze the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter. Findings The response surface model is used to predict the input factors influencing the delamination on the machined surfaces of the ARALL composite at different cutting conditions with the chosen range of 95 percent confidence intervals. Analysis of the influences of entire individual input machining parameters on the delamination has been carried out using RSM. Originality/value The effect of delamination on drilling of ARALL composites with solid carbide tools of various diameters has not been analyzed yet using RSM.

A Study of the Micro-End Milling of Titanium Alloy

2011 ◽  
Vol 325 ◽  
pp. 588-593 ◽  
Author(s):  
Koji Tsuda ◽  
Koichi Okuda ◽  
Hiroo Shizuka ◽  
Masayuki Nunobiki
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Tool Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Small Diameter ◽  
End Mill ◽  
High Speeds ◽  
Micro End Mill ◽  
Micro End Milling

This study deals with the cutting characteristics of titanium materials when milled by a small-diameter end mill, or a micro end mill. It is well known that titanium is difficult to cut by conventional means. However, its cutting characteristics have not yet been made sufficiently clear in cases where a micro end mill less than 1 mm in diameter is used. This study chiefly involves the experimental investigation of tool wear and surface roughness of micro-end milling of Ti-6Al-4V. The findings were that tool wear did not increase much when the cutting speed was increased from 50 m/min to 200 m/min. Furthermore, the cutting force required to cut decreased at high speeds and during wet cutting. In wet cutting, the surface had a roughness (Rz) of only 0.3 μm at 200 m/min in contrast to 0.6 μm at 50 m/min.

Surface Roughness Model when Machining Aluminum Nitride Ceramic with Two Flute Square End Micro Grain Solid Carbide End Mill

2013 ◽  
Vol 747 ◽  
pp. 282-286 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Alexander Gorin ◽  
K.A. Abou-El-Hossein ◽  
D. Sujan
Keyword(s):  
Surface Roughness ◽  
Aluminum Nitride ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
End Mill ◽  
Roughness Model ◽  
Solid Carbide

This research presents the performance of Aluminum Nitride ceramic in end milling using two flute square end micro grain solid carbide end mill under dry cutting. Surface finish is one of the important requirements in the machining process. This paper describes mathematically the effect of cutting parameters on surface roughness in end milling process. The quadratic model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using the response surface methodology (RSM). Design of experiments approach was employed in developing the surface roughness model in relation to cutting parameters. The predicted results are in good agreement with the experimental results within the specified range of cutting conditions. Experimental results showed surface roughness increases with increase in the cutting speed, feed rate, and the axial depth of cut.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

Surface Roughness Analysis for Radius End Mill in Cross Feed Direction Both Contour and Scanning Line Machinings

2020 ◽  
Author(s):  
Hirohisa Narita
Keyword(s):  
Surface Roughness ◽  
Inclination Angle ◽  
End Milling ◽  
Contour Line ◽  
End Mill ◽  
Good Surface ◽  
Corner Radius ◽  
Feed Direction ◽  
Scanning Line ◽  
Influence Degree

Abstract An optimum experimental condition, which realize good surface roughness in cross direction both contour and scanning lines, for radius end mill against some inclined surfaces is obtained and some features is these cutting processes is discussed in this paper. The optimum experimental condition, which consists of cutting type (or feed direction), spindle speed, feed rate, depth of immersion, inclination angle, corner radius of end mill and cross feed, is obtained and the influence degree of these parameters is calculated by using Taguchi method. The experiment is carried out based on L18 orthogonal array. Based on the influence degree and geometric contact status due to unique shape of radius end mill, some feature of radius end milling is introduced. As a result of the contour line machining, a scallop height is very influenced by the inclination angle and the corner radius, and surface machined by bottom edge must not be remained. Regarding the scanning line machining, “go-up” is good for the feed direction. Big corner radius is also suitable because side edge does not contact to workpiece. In other words, the cutting force in radial direction becomes small. Furthermore, the surface roughness of the scanning line machining is smaller than the one of the contour line machining.

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