Optimization of Machining Process Parameters in Drilling of CFRP Using Multi-Objective Taguchi Technique, TOPSIS and RSA Techniques

2017 ◽  
Vol 25 (3) ◽  
pp. 185-192 ◽  
Author(s):  
K. Shunmugesh ◽  
K. Panneerselvam
Keyword(s):  
Mathematical Model ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Weight Ratio ◽  
High Strength ◽  
Performance Characteristics ◽  
Machining Process ◽  
Taguchi Technique ◽  
Multi Objective

Carbon Fiber Reinforced Polymer (CFRP) are widely used in many engineering applications as replacement for various other elements to make use of the advantage of its high strength-weight ratio, durability and high corrosion resistance. The paper herein is an attempt to evaluate the drilling characteristics of CFRP by means of three different drill bit types (HSS, TiAlN and TiN) using Taguchi L27 (313) orthogonal array under dry condition. Firstly, the machining process parameters (cutting speed and feed rate) are optimized with multiple performance characteristics using Multi-objective Taguchi technique and TOPSIS. Secondly, mathematical model is developed to correlate the machining process parameters and the performance characteristics (surface roughness, circularity and cylindricity) using response surface analysis. ANOVA is used to validate the developed mathematical model of the responses. The investigation reveals that the results of TOPSIS technique are in good agreement with the multi-objective Taguchi technique and also feed rate is the most predominant factor which affects the responses.

scholarly journals Optimization of Drilling Process Parameters Via Taguchi, TOPSIS and RSA Techniques

2017 ◽  
Vol 62 (3) ◽  
pp. 1803-1812 ◽  
Author(s):  
K. Shunmugesh ◽  
K. Panneerselvam
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Speed ◽  
High Strength ◽  
Drilling Process ◽  
Drill Bit ◽  
Influence Of Process Parameters ◽  
Light Trucks ◽  
Cfrp Composite

AbstractCarbon Fiber Reinforced Polymer (CFRP) is the most preferred composite material due to its high strength, high modulus, corrosion resistance and rigidity and which has wide applications in aerospace engineering, automobile sector, sports instrumentation, light trucks, airframes. This paper is an attempt to carry out drilling experiments as per Taguchi’s L27(313) orthogonal array on CFRP under dry condition with three different drill bit type (HSS, TiAlN and TiN). In this research work Response Surface Analysis (RSA) is used to correlate the effect of process parameters (cutting speed and feed rate) on thrust force, torque, vibration and surface roughness. This paper also focuses on determining the optimum combination of input process parameter and the drill bit type that produces quality holes in CFRP composite laminate using Multi-objective Taguchi technique and TOPSIS. The percentage of contribution, influence of process parameters and adequacy of the second order regression model is carried out by analysis of variance (ANOVA). The results of experimental investigation demonstrates that feed rate is the pre-dominate factor which affects the response variables.

scholarly journals Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 289 ◽  
Author(s):  
Antonio Rubio-Mateos ◽  
Asuncion Rivero ◽  
Eneko Ukar ◽  
Aitzol Lamikiz
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Milling Process ◽  
Machining Process ◽  
Butadiene Rubber ◽  
Compression Tests ◽  
Compressive Behavior ◽  
Finishing Processes

In finishing processes, the quality of aluminum parts is mostly influenced by static and dynamic phenomena. Different solutions have been studied toward a stable milling process attainment. However, the improvements obtained with the tuning of process parameters are limited by the system stiffness and external dampers devices interfere with the machining process. To deal with this challenge, this work analyzes the suitability of elastomer layers as passive damping elements directly located under the part to be machined. Thus, exploiting the sealing properties of nitrile butadiene rubber (NBR), a suitable flexible vacuum fixture is developed, enabling a proper implementation in the manufacturing process. Two different compounds are characterized under axial compression and under finishing operations. The compression tests present the effect of the feed rate and the strain accumulative effect in the fixture compressive behavior. Despite the higher strain variability of the softer rubber, different milling process parameters, such as the tool feed rate, can lead to a similar compressive behavior of the fixture regardless the elastomer hardness. On the other hand, the characterization of these flexible fixtures is completed over AA2024 floor milling of rigid parts and compared with the use of a rigid part clamping. These results show that, as the cutting speed and the feed rate increases, due to the strain evolution of the rubber, the part quality obtained tend to equalize between the flexible and the rigid clamping of the workpiece. Due to the versatility of the NBR for clamping different part geometries without new fixture redesigns, this leads to a competitive advantage of these flexible solutions against the classic rigid vacuum fixtures. Finally, a model to predict the grooving forces with a bull-nose end mill regardless of the stiffness of the part support is proposed and validated for the working range.

Multi-Objective Optimization on Drilling of Titanium Alloy (Ti6Al4V)

2013 ◽  
Vol 763 ◽  
pp. 29-49 ◽  
Author(s):  
A. Prabukarthi ◽  
V. Krishnaraj ◽  
M. Senthil Kumar
Keyword(s):  
Titanium Alloy ◽  
Thrust Force ◽  
Optimization Technique ◽  
Weight Ratio ◽  
High Strength ◽  
Hole Diameter ◽  
Machining Process ◽  
Multi Objective ◽  
Titanium Alloy Ti6al4v ◽  
Exit Burr

Titanium alloys present superior properties like resistance to corrosion, high strength to weight ratio etc, but possess poor machinability. Titanium alloy Ti-6Al-4V is the most commonly used titanium alloy in aerospace and medical device industries. Titanium and its alloys are notorious for their poor thermal properties and are classified as difficult-to-machine materials. Drilling is an important machining process since it is involved in nearly all titanium applications. It is desirable to develop optimized drilling processes for Ti and improve the hole characteristics such as hole diameter, circularity and exit burr of currently available processes. Due to the low machinability of the alloys under study, selecting the machining conditions and parameters is crucial. The range of spindle speed and feed rate, which provide a satisfactory tool life, is very limited. The hole quality (hole diameter and circularity), thrust force, torque and exit burr were evaluated at various spindle speeds, feed rates combinations. The optimized parameter is chosen using the multi-objective weighted sum optimization technique.

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.

scholarly journals Analysis and Optimization of Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6106
Author(s):  
Waleed Ahmed ◽  
Hussien Hegab ◽  
Atef Mohany ◽  
Hossam Kishawy
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inclination Angle ◽  
Feed Rate ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Hardened Steel ◽  
Machining Process ◽  
Aisi 4140 ◽  
Steel Aisi

It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. Machining with self-propelled rotary tools (SPRT) is considered one of the promising techniques used to provide proper tool life even under dry conditions. In this work, an attempt has been performed to analyze, model, and optimize the machining process of AISI 4140 hardened steel using self-propelled rotary tools. Experimental analysis has been offered to (a) compare the fixed and rotary tools performance and (b) study the effect of the inclination angle on the surface quality and tool wear. Moreover, the current study implemented some artificial intelligence-based approaches (i.e., genetic programming and NSGA-II) to model and optimize the machining process of AISI 4140 hardened steel with self-propelled rotary tools. The feed rate, cutting velocity, and inclination angle were the selected design variables, while the tool wear, surface roughness, and material removal rate (MRR) were the studied outputs. The optimal surface roughness was obtained at a cutting speed of 240 m/min, an inclination angle of 20°, and a feed rate of 0.1 mm/rev. In addition, the minimum flank tool wear was observed at a cutting speed of 70 m/min, an inclination angle of 10°, and a feed rate of 0.15 mm/rev. Moreover, different weights have been assigned for the three studied outputs to offer different optimized solutions based on the designer’s interest (equal-weighted, finishing, and productivity scenarios). It should be stated that the findings of the current work offer valuable recommendations to select the optimized cutting conditions when machining hardened steel AISI 4140 within the selected ranges.

scholarly journals Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 840 ◽  
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li ◽  
Mozammel Mia
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Desirability Function ◽  
Interactive Effect ◽  
Cutting Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Depth Of Cut

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

NC Turning Process Parameters Optimization Based on Simulation Software

2012 ◽  
Vol 271-272 ◽  
pp. 452-456
Author(s):  
Shu Feng Sun ◽  
Ping Ping Wang ◽  
Xin Wu ◽  
Sen Lin
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Simulation Software ◽  
Parameters Optimization ◽  
Machining Process ◽  
Optimum Process ◽  
Finite Element Software

Machining process parameters are main factors influencing machining quality and efficiency. Finite element models of tool and part are set up using finite element software Deform-3D. Variety laws of cutting force and temperature under different process parameters are simulated. The results are analyzed. Cutting force grows obviously with the growth of cutting speed (vc). However, cutting force fluctuates and decreases with the growth of cutting depth (ap) indicating the phenomenon of work hardening. Cutting force fluctuates and grows with the growth of feed rate ( f ). But the influence of feed rate ( f ) to cutting force is smaller than that of cutting speed (vc). The growths of the above mentioned three process parameters all cause the rise of temperature. Machining simulation research provides the optimum process parameters for CNC programming.

scholarly journals Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

2021 ◽  
Vol 3 (7) ◽  
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Positive Response ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Force Model ◽  
Sic Particles

Abstract In this study, the proposed experimental and second-order model for the cutting forces were developed through several parameters, including cutting speed, feed rate, depth of cut, and two varying content of SiCp. Cutting force model was developed and optimized through RSM and compared for two different percentages of components SiCp/Al 45% and SiCp/Al 50%. ANOVA is used for Quantitative evaluation, the main effects plot along with the evaluation using different graphs and plots including residual analysis, contour plots, and desirability functions for cutting forces optimization. It provides the finding for choosing proper parameters for the machining process. The plots show that during increment with depth of cut in proportion with feed rate are able to cause increments in cutting forces. Higher cutting speed shows a positive response in both the weight percentage of SiCp by reducing the cutting force because of higher cutting speed increases. A very fractional increasing trend of cutting force was observed with increasing SiCp weight percentages. Both of the methods such as experiment and model-predicted results of SiCp/Al MMC materials were thoroughly evaluated for analyzing cutting forces of SiCp/Al 45%, and SiCp/Al 50%, as well as calculated the error percentages also found in an acceptable range with minimal error percentages. Article Highlights This study focuses on the effect of cutting parameters as well as different percentage of SiC particles on the cutting forces, while comparing the results of both SiC particles such as SiCp/Al 45%, and SiCp/Al 50% the result shows that there isn’t fractional amount of impact on the cutting force with nominal increasing percentages of SiC particles. Cutting speed in machining process of SiCp/Al shows positive response in reducing the cutting forces, however, increasing amount of depth of cut followed by increasing feed rate creates fluctuations in cutting force and thus increases the cutting force in the cutting process. The developed RSM mathematical model which is based on the box Behnken design show excellent competence for predicting and suggesting the machining parameters for both SiCp/Al 45%, and SiCp/Al 50% and the RSM mathematical model is feasible for optimization of the machining process with good agreement to experimental values.

CNC Machining and Simulation for Relief of Special-Shaped Stone

2012 ◽  
Vol 468-471 ◽  
pp. 69-73
Author(s):  
Yu Hou Wu ◽  
Hui Jie You ◽  
De Hong Zhao ◽  
Yan Liu
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Tool Path ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Cnc Machining ◽  
Machining Process ◽  
Cutting Depth ◽  
Machining Center ◽  
Turn Milling

Use special-shaped stone turn-milling machining center (HTM50200) to achieve the production of complex relief. Through the ArtCAM establish the three dimensional relief model of Riverside Scene at Qingming Festival. Analysis of blank material characteristics and features of NC machining center, select the appropriate tool, calculate cutting depth 、cutting speed 、feed rate 、spindle speed and other process parameters by formulas. With ArtCAM/CAM module to make process of the preparation of the rough finishing, the semi-finishing and finishing, and then generate the tool path file. Simulation in VERICUT can optimize the potential collision, over-cutting and owe cut of the machining process, and the adoption of special-shaped stone machining center for milling to finalize production of the relief, summarize the experience in special-shaped stone processing.

scholarly journals Optimization of Process Parameters with Minimum Thrust Force and Torque in Drilling Operation Using Taguchi Method

2014 ◽  
Vol 6 ◽  
pp. 925382 ◽  
Author(s):  
Suleyman Neseli
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Helix Angle ◽  
Machining Process ◽  
Low Thrust ◽  
Taguchi Optimization

This research outlines the Taguchi optimization methodology, which is applied to optimize cutting parameters in drilling of AISI 1040 steel. The drilling parameters evaluated are cutting speed, feed rate, and helix angle. Series of experiments are conducted to relate the cutting parameters on the thrust force and torque. L27(313) orthogonal array, signal-to-noise ratio is employed to analyze the influence of these parameters on thrust force and torque during drilling. Analysis of variance (ANOVA) is used to study the effect of process parameters on machining process. The study shows that the Taguchi method is suitable to solve the stated problem with the minimum number of trials. The main objective is to find the important factors and combination of factors that influence the machining process to achieve low thrust force and torque. The analysis of the Taguchi method indicates that the feed rate is the most significant factor affecting the thrust force, while the cutting speed contributes the most to the torque.

Sign in / Sign up

Export Citation Format

Share Document