Tool-Life Testing by Response Surface Methodology—Part 2

1964 ◽  
Vol 86 (2) ◽  
pp. 111-116 ◽  
Author(s):  
S. M. Wu
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Tool Life ◽  
Statistical Significance ◽  
Cutting Speed ◽  
Order Effect ◽  
Second Order ◽  
First Order ◽  
Independent Variable ◽  
Basic Philosophy

This paper is a continuation of a previous paper in which the basic philosophy of response surface methodology has been explained and a first-order tool-life-predicting equation has been developed. This part of the paper illustrates the development of a second-order tool-life-predicting equation in 18 and 24 tests. It was found that the second-order effect did not show statistical significance within the cutting ranges of this project; however, the second-order effect of cutting speed has been found important by the study of residuals. If only one independent variable is investigated, a minimal number of tests can be used to find a second-order equation. Examples of designs in three, five, and six tests are illustrated.

Modeling and Experimental Study on Cutting Force of Diamond Circular Saw in Cutting Granite Using Response Surface Methodology

2013 ◽  
Vol 652-654 ◽  
pp. 2191-2195 ◽  
Author(s):  
Zheng Mei Zhang ◽  
Hai Wen Xiao ◽  
Gui Zhen Wang ◽  
Shu Zhong Zhang ◽  
Shu Qin Zhang
Keyword(s):  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Feed Rate ◽  
Cutting Speed ◽  
Feed Speed ◽  
Machining Parameters ◽  
Cutting Depth ◽  
First Order ◽  
Circular Saw

Based on experiment of sawing Wulian red granite with diamond circular saw, the relations between the cutting force with machining parameters are studied. Cutting speed, feed rate and cutting depth are considered as the process parameters. The cutting force in sawing granite operation are measured and the experimental results are then analyzed using response surface methodology. From the analysis, it is seen that the cutting force Fx , Fy and Fz are reduced with the increase of cutting speed and increased with the increase of feed rate and cutting depth, and the mathematical models of the cutting force are developed. By ANOVA for the cutting force models, It is concluded that the models are significant at 95% confidence level and the significant effects are the first-order of cutting speed, feed speed, cutting depth and the quadratic of cutting depth.

Multi-Objective Optimization Using Box-Behken of Response Surface Methodology for High-Speed Machining of Inconel 718

2014 ◽  
Vol 629 ◽  
pp. 487-492 ◽  
Author(s):  
Mohd Shahir Kasim ◽  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
E. Mohamad ◽  
Raja Izamshah ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Milling

This study was carried out to investigate how the high-speed milling of Inconel 718 using ball nose end mill could enhance the productivity and quality of the finish parts. The experimental work was carried out through Response Surface Methodology via Box-Behnken design. The effect of prominent milling parameters, namely cutting speed, feed rate, depth of cut (DOC), and width of cut (WOC) were studied to evaluate their effects on tool life, surface roughness and cutting force. In this study, the cutting speed, feed rate, DOC, and WOC were in the range of 100 - 140 m/min, 0.1 - 0.2 mm/tooth, 0.5 - 1.0 mm and 0.2 - 1.8 mm, respectively. In order to reduce the effect of heat generated during the high speed milling operation, minimum quantity lubrication of 50 ml/hr was used. The effect of input factors on the responds was identified by mean of ANOVA. The response of tool life, surface roughness and cutting force together with calculated material removal rate were then simultaneously optimized and further described by perturbation graph. Interaction between WOC with other factors was found to be the most dominating factor of all responds. The optimum cutting parameter which obtained the longest tool life of 60 mins, minimum surface roughness of 0.262 μm and resultant force of 221 N was at cutting speed of 100 m/min, feed rate of 0.15 mm/tooth, DOC 0.5 m and WOC 0.66 mm.

scholarly journals Useful Numerical Statistics of Some Response Surface Methodology Designs

2016 ◽  
Vol 8 (4) ◽  
pp. 40
Author(s):  
Iwundu M. P.
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Optimality Criteria ◽  
Second Order ◽  
First Order ◽  
Central Composite Designs ◽  
Alphabetic Optimality ◽  
Main Effects ◽  
Composite Designs ◽  
Central Composite

<p>Useful numerical evaluations associated with three categories of Response Surface Methodology designs are presented with respect to five commonly encountered alphabetic optimality criteria. The first-order Plackett-Burman designs and the  Factorial designs are examined for the main effects models and the complete first-order models respectively. The second-order Central Composite Designs are examined for second-order models. The A-, D-, E-, G- and T-optimality criteria are employed as commonly encountered optimality criteria summarizing how good the experimental designs are. Relationships among the optimality criteria are pointed out with regards to the designs and the models. Generally the designs do not show uniform preferences in terms of the considered optimality criteria. However, one interesting finding is that central composite designs defined on cubes and hypercubes with unit axial distances are uniformly preferred in terms of E-optimality and G-optimality criteria.</p>

Tool-Life Testing by Response Surface Methodology—Part 1

1964 ◽  
Vol 86 (2) ◽  
pp. 105-110 ◽  
Author(s):  
S. M. Wu
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Tool Life ◽  
Statistical Approach ◽  
Order Equation ◽  
New Technique ◽  
Depth Of Cut ◽  
Life Testing ◽  
First Order ◽  
Independent Variables

This paper presents a study of tool-life testing by a statistical approach, referred to as response surface methodology, instead of the conventional one-variable-at-a-time method. With this new technique the number of tests required to develop a tool-life predicting equation can be substantially reduced. The reliability of such an equation can also be estimated. Three independent variables, speed, feed, and depth of cut, were investigated in this project. A simple first order equation is “graduated” in Part 1 and a more general second-order equation will be presented in Part 2 of this study.

scholarly journals Research on tool wear factors for milling wood-plastic composites based on response surface methodology

BioResources ◽  
2020 ◽  
Vol 16 (1) ◽  
pp. 151-162
Author(s):  
Weihua Wei ◽  
Yingli Li ◽  
Yuantong Li ◽  
Yiqi Xu ◽  
Changyong Yang
Keyword(s):  
Response Surface Methodology ◽  
Tool Wear ◽  
Response Surface ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Feed Speed ◽  
Cutting Depth ◽  
Wood Plastic Composites ◽  
Plastic Composites

A high-speed milling experiment on wood-plastic composites was performed using cemented carbide tools, and the resulting wear pattern was studied. The influence of the cutting parameters, the cutting speed, feed speed, and axial cutting depth on the tool wear was studied via response surface methodology, and the influence of the interaction of the cutting parameters on tool wear was analyzed. Three-dimensional surface graphs and contour plots of the tool wear results were established. According to the experimental results, a mathematical model of the tool wear based on the second-order response surface methodology was established, and the model was utilized to verify its feasibility. The results show that the nose width (NW) increases with the increase of the cutting speed and axial cutting depth and decreases with the increase of feed speed. Among the factors affecting tool wear, the cutting speed had the greatest influence, followed by the feed rate, with the axial cutting depth affecting tool wear the least. According to the results of the interaction between the tool wear and the cutting parameters, a low feed speed and small axial cutting depth can be selected to ensure long tool life; for low-speed cutting, a high feed speed and large axial cutting depth can be adopted to ensure tool life while improving machining efficiency.

Quantification of tool chatter and metal removal rate using wavelet denoising and statistical approach

2018 ◽  
Vol 49 (2) ◽  
pp. 62-81 ◽  
Author(s):  
Shailendra Kumar ◽  
Bhagat Singh
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Removal ◽  
Removal Rate ◽  
Statistical Significance ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Metal Removal Rate ◽  
Chatter Index ◽  
Tool Chatter

Tool chatter is an unavoidable phenomenon encountered in machining processes. Acquired raw chatter signals are contaminated with various types of ambient noises. Signal processing is an efficient technique to explore chatter as it eliminates unwanted background noise present in the raw signal. In this study, experimentally recorded raw chatter signals have been denoised using wavelet transform in order to eliminate the unwanted noise inclusions. Moreover, effect of machining parameters such as depth of cut ( d), feed rate ( f) and spindle speed ( N) on chatter severity and metal removal rate has been ascertained experimentally. Furthermore, in order to quantify the chatter severity, a new parameter called chatter index has been evaluated considering aforesaid denoised signals. A set of 15 experimental runs have been performed using Box–Behnken design of experiment. These experimental observations have been used to develop mathematical models for chatter index and metal removal rate considering response surface methodology. In order to check the statistical significance of control parameters, analysis of variance has been performed. Furthermore, more experiments are conducted and these results are compared with the theoretical ones in order to validate the developed response surface methodology model.

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.

Fiber laser processing of GFRP composites and multi-objective optimization of the process using response surface methodology

2018 ◽  
Vol 53 (11) ◽  
pp. 1459-1473 ◽  
Author(s):  
Shiva Dayal Rao B ◽  
Abhijeet Sethi ◽  
Alok Kumar Das
Keyword(s):  
Response Surface Methodology ◽  
Fiber Laser ◽  
Response Surface ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Cutting Speed ◽  
Kerf Width ◽  
Laser Irradiance ◽  
Input Process ◽  
Cut Surface

In the present investigation, a continuous wave fiber laser with maximum power of 400 W was used to cut a glass fiber reinforced plastic sheet of 4.56 mm thickness using Nitrogen as assisting gas. The influence processing parameters such as laser irradiance, gas pressure, and cutting speed on the cut surface quality were investigated by using response surface methodology. The different responses of laser cut surface such as upper kerf width, taper percentage along the cut depth, and heat-affected zone on the top surface were measured to analyze the influence of input process parameters on the responses. A statistical analysis on the obtained results was conducted and found that the optimum values of different input process parameters were laser irradiance: 8.28 × 105 watt/cm2, cutting speed: 600 mm/min and assisting gas pressure: 7.84 bar. The corresponding values of responses were upper kerf width: 177.4 µm, taper 0.73%, and heat-affected zone on top surface: 109.23 µm. The confirmation experiments were conducted with the obtained optimum parameter setting and observed that the predicted values and experimental values for upper kerf width, taper percentage and top surface heat-affected zone were within the error limits of 2.52%, 1.84%, and 0.45%, respectively. Furthermore, damages like loose fibers, interlayer fractures, evaporation of matrix material and fiber breakages were observed.

scholarly journals Effect of Process Parameters on the Surface Roughness and Kerf Width of Mild Steel during Plasma Arc Cutting Using Response Surface Methodology

2020 ◽  
Vol 5 (1) ◽  
Author(s):  
Ekhaesomi A Agbonoga ◽  
Oyewole Adedipe ◽  
Uzoma G Okoro ◽  
Fidelis J Usman ◽  
Kafayat T Obanimomo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Analysis Of Variance ◽  
Process Parameters ◽  
Cutting Speed ◽  
Gas Pressure ◽  
Kerf Width ◽  
Plasma Arc ◽  
Plasma Arc Cutting

This study investigated the effects of process parameters of plasma arc cutting (PAC) of low carbon steel material using analysis of variance. Three process parameters, cutting speed, cutting current and gas pressure were considered and experiments were conducted based on response surface methodology (RSM) via the box-Behnken approach. Process responses viz. surface roughness (Ra) and kerf width of cut surface were measured for each experimental run. Analysis of Variance (ANOVA) was performed to get the contribution of process parameters on responses. Cutting current has the most significant effect of 33.43% on the surface roughness and gas pressure has the most significant effect on  kerf width of  41.99% . For minimum surface roughness and minimum kerf width, process parameters were optimized using the RSM. Keywords: Cutting speed, cutting current, gas pressure,   surface roughness, kerf width

scholarly journals OPTIMIZATION OF LEVOFLOXACIN REMOVAL FROM AQUEOUS SOLUTION USING ELECTROCOAGULATION PROCESS BY RESPONSE SURFACE METHODOLOGY

2021 ◽  
Vol 52 (1) ◽  
pp. 204-217
Author(s):  
Mohammed & Mohammed-Ridha
Keyword(s):  
Aqueous Solution ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Correlation Coefficient ◽  
Iron Hydroxide ◽  
Second Order ◽  
Experimental Results ◽  
Order Kinetic ◽  
Experimental Conditions ◽  
Good Agreement

This study was aimed to investigate the response surface methodology (RSM) to evaluate the effects of various experimental conditions on the removal of levofloxacin (LVX) from the aqueous solution by means of electrocoagulation (EC) technique with stainless steel electrodes. The EC process was achieved successfully with the efficiency of LVX removal of 90%. The results obtained from the regression analysis, showed that the data of experiential are better fitted to the polynomial model of second-order with the predicted correlation coefficient (pred. R2) of 0.723, adjusted correlation coefficient (Adj. R2) of 0.907 and correlation coefficient values (R2) of 0.952. This shows that the predicted models and experimental values are in good agreement. The results of the kinetic study showed that the second-order kinetic model was in good agreement with the experimental results and suggested that the mechanism of chemisorption controlled the LVX adsorption. The experimental results indicated that the adsorption of LVX on iron hydroxide flocs follows Sips isotherm with the value of the correlation coefficient (R2) of 0.937. Sips isotherm shows that both homogenous and heterogeneous adsorption can occur.

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